Maxidome

Participants
Skills	construction, grinding, drilling
Status	Active
Niche	Mechanics
Purpose	Infrastructure
Tool	No
Location
Cost
Tool category

IMG_20150807_205134.jpg {{#if:No | [[Tool Owner::{{{ProjectParticipants}}} | }} {{#if:No | [[Tool Cost:: | }}

Frame construction

Tubing

30 x 'S' : 1.57m x 22mm steel
40 x 'M' : 1.82m x 22mm steel
50 x 'L' : 1.86m x 22mm steel

Hubs

46x 40mm steel ring
25 x 6-way rings
6 x 5-way rings
15 x 4-way rings

Construction of full scale ziptie hub prototype

Take 75mm ring with 24mm drilled holes, 40mm inner hub ring, strut and ziptie.
Ziptie ring in 8mm drilled holes.
Continue as above.
Make sure to leave ~5mm on the ziptie when cutting short so the catch cannot slip so easily.

Fasteners

7 mm wide zipties
Grommets
Tent rope

Cover construction

Container construction

We need one or more containers to be able to transport the dome in. Before we can build a container we need to figure out what the optimal design would be. A wooden crate? Multiple wooden crates? Plastic bag? Duffelbag? Plz help think

Design decisions

The dome will be 9m in diameter
The tubes will be 22m steel tubes
The inner ring of the hub will be a 40mm external diameter steel ring, with a height of 25 mm.
The outer ring of the hub will be a 75mm external diameter PVC ring, with a height of 50mm.
Both ends of a steel pipe will be equipped with a 8mm hole, with it's centerpoint located 8mm from the edge.
The outer hub will be equipped with 24mm holes.
The short pipes (A) are marked with BLACK tape
The medium pipes (B) are marked with WHITE tape
The long pipes (C) are marked with RED tape
140 grommets are needed
60 herrings are needed
Special tape is used to provide "meat" to mount the grommets on the cover

TODO

Frame construction

~~Acquire missing tools needed~~
~~Settle on size~~
~~Settle on tube diameter~~
~~Settle on hub design~~
~~Determine total length of tubing required~~
~~Find supply of steel tubing~~
Design hubcap
Print hubcaps
~~Purchase tubes~~
~~Select zipties~~
~~Purchase zipties~~
~~Cut tubes to required lengths~~
~~Mark tubes according to type~~
~~Deburr pipes~~
~~Drill tube ends so zipties can be fitted~~
Order rebar
Create assembly plan
Assemble in back yard
Settle on container solution (how are we going to transport the fucker?)

Cover construction

~~Request a sample of hermetix from supplier~~
~~Validate Hermetix as viable covering candidate.~~ We'll see when we get it
~~Decide on covering material~~
~~Find supply of covering material~~
~~Decide on how to bind the shapes together~~
~~Find the appropriate grommets to mount in the cover in order to rope the covering down (10 mm? 20 mm?) 10mm~~
~~Determine how many grommets are needed~~
~~Order grommets~~
~~Order grommet fastening tool, if the one we have does not fit~~
~~Order special tape like fabric to strengthen the joint between the cover and the grommet~~
~~Calculate how much rope we need~~ 200m should be enough
~~Order rope~~
~~Find a method to cut holes in the fabric in order the mount the rivets~~
~~Determine amount of herrings~~
~~Order herrings~~
Extract required shapes from material
Create cool showoffy idiopolis artsy design for covering

Container construction

Settle on container type
Design containers?
Build containers

Construction

Start with a 5-way connector and put 5 S tubes around it. Tip these with 6-way connectors, and connect them with 5 M's to form five MSS triangles, putting the covers on the M pipes here oriented with the seams inwards.
Add two L tubes to each of the outlying 6-ways leaving the last connection free. Connect these at the ends into five LLM triangles with more 6-way connectors.
Fill up that last space with M tubes, and end those with 6-way connectors. Join all the outlying 6-way connectors up with more A tubes to make 10 more LLM triangles. This will lift the dome.
Unfurl the covers down to the next layer and connect them with bolts.
Attach internal guttering to seams
Any 6-way with just L pipes to it, add two more L pipes. Any others, put two M pipes around it leaving the centre free.
Make 5 more 5-way connectors with three S-tubes and put the middle to the remaining spaces where the B-tubes join. Then use more 6-way connectors to join up the next outer pair and form 10 more LLM and 10 MSS triangles.
Lift the centre of the dome and connect the new 6-way connectors from above with an M-pipe.
Add middle node to constrcution and spool out power cable for nodes
Unfurl the covers down to the next layer and connect them with bolts.
Extend internal guttering to seams
Lift the pentagonal top face in now and tie it down to the lowest pipes.
Construct the full outer ring made of LLM triplets in five sets. Line up the M-pipes with the five-way hubs.
Get five people to lift the dome at the five 5-way hubs. When this is done, position and pin in the last layer with pipes so that:

 * S pipes go to 5-way hubs
 *Any 4-way hub with S pipes has only M as its partner
 * All others are L-pipes.

Unfurl the covers down to the next layer and connect them with bolts.
Extend internal guttering to seams
Hammer in ten fishhooks around the dome to keep it down.
Use pipe lagging to define a door or two

Cost

Pipes 396 euro
Covering material (Hermetix) 137 euro
Hubrings: 1 node
Zipties 20 euro
200m Shavelines: 63 euro
60 herrings: 12 euro
Mounting tape for sailrings: 10.5 euro
140 Sailrings 21.80
Sailring mount tool + shipping: 10

Total: 670.30 euro

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