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Starting In on Buiding a Dome!

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#51 Acer

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Posted 31 October 2019 - 07:41 PM

@ philipdehazya

TiG is a much cleaner process than MiG or Stick which have a lot of splatter that can be on the warm side..  lol

 

I admire anyone who can weld in their shorts!

 

I needed a tan anyway lol.gif .

The UV did get to me a little.



#52 Acer

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Posted 31 October 2019 - 07:45 PM

Hey if you're interested, I have 3000 yes 3000 ft of SILK fiberglass  commonly used for sail plane skin.

I would sell you enough to skin the out side twice ... for cheap.... if you want to go that route.

It's over 4 ft wide on the roll.  I could send you a sample and let you decide.

Email me off line and I will get right back.

 

When applied right, it would be super strong, and smooth.  With an epoxy coat of paint, stay smooth and shiny and maintenance  free for many many years....

Steveg.

I appreciate the offer, but I am all finished with installing the wire screen.



I picked up the acrylic stucco today and made a test sample.  I really think it will work well!  I then caulked all the edges of the foam where it meets the wood to seal any gaps left and sanded down the dome for to get it ready for stucco.

 

Tomorrow I'll be applying the stucco to the exterior of the dome, then I need to do the same thing to the inside (apply screen material and stucco).

It is finally coming together.

 

 

48993749172_54f00108eb_o.jpgIMG_20191031_162942-01 by Colo CJ, on Flickr


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#53 Stevegeo

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Posted 31 October 2019 - 08:06 PM

For what it's worth,  silk glass can be applied over screen, it adds dimementional stability and added strength. 

I have built a few projects with this method , using fine screen door screen  ( plastic), metal window screen, up to chicken wire ..

Your stuco will be stunning when finished . And should last a long time , needing only a touch up every few years.

Btw I happen to live in a geodesic dome I built myself. 40 ft  3v  5/8th sphere on a riser wall .. so I appreciate  the work you've put into this . Great job! 



#54 Acer

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Posted 01 November 2019 - 08:26 PM

I stucco'd one side today.  The color was just what I was looking for, kind of a light tan/adobe. 

 

Once I get the dome fully stucco'd I am going to paint the exposed wood a different color.  Not sure what color yet, probably some shade of grey.

 

48997508618_ef4bc48b05_o.jpgIMG_20191101_160502-01 by Colo CJ, on Flickr


Edited by Acer, 01 November 2019 - 08:27 PM.

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#55 rimcrazy

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Posted 02 November 2019 - 07:24 AM

Looks very nice.  Sweet job.  Maybe you answered this but how heavy is that an how are you going to move it in place?



#56 Acer

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Posted 02 November 2019 - 09:37 AM

Looks very nice.  Sweet job.  Maybe you answered this but how heavy is that an how are you going to move it in place?

I think the dome itself will be around 250 lbs.  The base shouldn't be very heavy.

 

I'll just get my dad to help me lift it onto the back of my truck to move it to my house. We are sandblasters so we are used to lifting 100+ lbs at a time over our head (I do that at least 20-30 times a day to fill my pot.


Edited by Acer, 02 November 2019 - 09:37 AM.

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#57 Acer

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Posted 06 November 2019 - 07:00 PM

I finished applying the stucco to the dome today. The outside is a cream/adobe and the inside is a charcoal grey color.

 

Now onto building the shutter!

 

49026407196_f65d9006e0_c.jpgDSCF2064-1 by Colo CJ, on Flickr


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#58 mikerepp

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Posted 07 November 2019 - 08:05 AM

Sweet!   Looks good, nicely done!



#59 Stevegeo

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Posted 07 November 2019 - 09:17 AM

my question. not how heavy...but how easy will it be to rotate after its done ..
mine is same diameter .has steel plate around the perimeter. wheels are steel and mine moves with some effort ..all ball bearing..my dome is around 200lbs .

#60 Acer

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Posted 07 November 2019 - 09:22 AM

my question. not how heavy...but how easy will it be to rotate after its done ..
mine is same diameter .has steel plate around the perimeter. wheels are steel and mine moves with some effort ..all ball bearing..my dome is around 200lbs .

I can move it with one finger.  It easily rotates.

I am using 8 roller blade wheels and nice bearings.



#61 CCD-Freak

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Posted 07 November 2019 - 11:42 AM

I can move it with one finger.  It easily rotates.

I am using 8 roller blade wheels and nice bearings.

Do you have any problem with the roller blade wheels developing a flat spot when the dome sits in the same position for a long time?

 

The dome is looking great.

 

John

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#62 kathyastro

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Posted 07 November 2019 - 03:02 PM

Do you have any problem with the roller blade wheels developing a flat spot when the dome sits in the same position for a long time?

 

The dome is looking great.

 

John

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My Exploradome weighs about 180 lbs.  It sits on roller blade wheels, and they have shown no sign of flat spots.  It takes a 10 lb pull to get it rotating, and a 5 lb pull to keep it going.  That is a pretty light pull, and one hand does it easily. 

 

I measured the pull so I could calculate the torque for a stepper motor to rotate it.  If the stepper is unpowered, I can still easily rotate the dome with one hand against the cogging effect of the motor.

 

I would call the roller-blade wheels a success.


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#63 Tom K

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Posted 09 November 2019 - 08:21 PM

Looks awesome - I am looking forward to seeing this come together!



#64 Acer

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Posted 12 November 2019 - 08:43 PM

I designed and built the shutter today.

 

First, I got some 1 1/2" aluminum flat stock and glued/screwed them to the top of my dome opening.  The shutter will slide on top of the flats.

 

49057514457_d88dc8377a_c.jpgDSCF2065-1 by Colo CJ, on Flickr

 

Here is how I cut my plywood arcs.  I simply screwed a piece of angle iron to my router, then drilled holes in the angle iron to the right radius for both the inside and outside of the arcs.  Simple and repeatable results.

For the shutter, I just had to cut two arcs, so I cut them the length of a 4x8 sheet.  When I cut the arcs to make up the base and dome circles, I cut the arcs on the 4' side of the ply, which made much less waste.

 

49057516542_eb4e908fcc_c.jpgIMG_20191111_132500-01 by Colo CJ, on Flickr

 

The shutter was simple to make, just two arcs and some poplar 1x2 boards, glued and screwed.

 

49056784578_0fd1db6d16_c.jpgIMG_20191111_171151-01 by Colo CJ, on Flickr

 

Then I sheeted the opening with some thin ply.

 

49056782233_66bd325187_c.jpgDSCF2066-1 by Colo CJ, on Flickr

 

49056782198_6bf71b34be_c.jpgDSCF2067-1 by Colo CJ, on Flickr

 

The shutter rides on 6, 1 1/2" casters, that roll on the aluminum flat stock.  The aluminum flat stock hangs over the dome sides, and there are pieces of wood screwed on the shutter that ride under the aluminum overhang, which make solidly "captures" the shutter to the dome.

 

A photo from inside the dome showing the casters.

 

49056782298_5443525d93_c.jpgDSCF2070-1 by Colo CJ, on Flickr

I still have to take the shutter back off and finish sand it.  I will probably end up fiberglassing the outside of the shutter itself, then painting it.

I can finally see the end in sight!  After I finish the shutter, I need to make a door in the base, then take the base outside and shoot a coat of epoxy on it, then sheet it.  I could possibly be done with construction by the end of the week!


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#65 Cfreerksen

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Posted 12 November 2019 - 09:45 PM

I am really enjoying watching this build.

 

Chris



#66 TxStars

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Posted 12 November 2019 - 11:07 PM

The finish line is getting close for the dome..

Now you can start thinking about motorizing it..



#67 Stevegeo

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Posted 13 November 2019 - 04:10 PM

My dome had at one time thin lauwan like yours on the outside , covered in paint then aluminum...

That only lasted a year or so .. 

After a bit of rework and rethink I made the current ones of fiberglass  sheet  riveted to a welded bent conduit frame .

Extremely light weighing in at 5 lbs each .. dimensionally stable in hot or cold , something you won't know until its exposed to the extreme. 

If you decide to keep the wood , fiberglass the wood inside and out .. cover the entire grain with resin ... one small exposure left will let water into the wood and eventually  rot ... been there , done that ! 

So far you are doing great ...

Steveg 



#68 SteveGR

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Posted 14 November 2019 - 02:56 PM

My dome had at one time thin lauwan like yours on the outside , covered in paint then aluminum...

That only lasted a year or so .. 

After a bit of rework and rethink I made the current ones of fiberglass  sheet  riveted to a welded bent conduit frame .

Extremely light weighing in at 5 lbs each .. dimensionally stable in hot or cold , something you won't know until its exposed to the extreme. 

If you decide to keep the wood , fiberglass the wood inside and out .. cover the entire grain with resin ... one small exposure left will let water into the wood and eventually  rot ... been there , done that ! 

So far you are doing great ...

Steveg 

I agree about filling every little bit of grain with resin, at least that is what seemed to work for me, in my limited experiences with fiberglass.  Resin is your friend.  Your toxic, finicky, potentially flammable friend.  I didn't say it was a good friend, rather one to treat with a little skepticism and keep an eye on.


Edited by SteveGR, 14 November 2019 - 02:57 PM.

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#69 Acer

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Posted 18 November 2019 - 09:04 PM

I finished priming and painting the entire dome.  I live in a very dry climate (~ 15 inches of rain a year), so for now, I decided to just apply two coats of primer and two coats of paint to the exterior wood.  My house has the same paint and primer and it holding up to the weather very well.  All the edges and seams were first caulked fully before painting.

If it becomes a problem, I can strip it and fiberglass the exterior of the shutter and back side later.

49087360458_dc684bcf3f_c.jpgDSCF2075-1 by Colo CJ, on Flickr

 

I also am almost done with the base.  Today I finished applying the second coat of primer and started skinning it with corrugated metal. The interior will be insulated and paneled after the base is bolted down to the slab.

Tomorrow I should have to base completed, the door finished and installed and everything ready to bring home.

I am going to have to pour the slab as well.  I will probably start forming it up tomorrow or Wednesday. 

 

Here's the base.  I have it upside down while I am skinning it since it makes it a little easier.

 

49087360648_f992d11496_c.jpg[/url]DSCF2077-1 by Colo CJ, on Flickr


Edited by Acer, 18 November 2019 - 09:05 PM.

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#70 dmdouglass

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Posted 18 November 2019 - 10:42 PM

This is an amazing build. Anxious to see the finished product and first light report.



#71 TxStars

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Posted 19 November 2019 - 01:44 AM

@ Acer

You are making the pier and slab as two parts? correct?


Edited by TxStars, 19 November 2019 - 01:45 AM.


#72 Acer

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Posted 19 November 2019 - 09:45 AM



@ Acer

You are making the pier and slab as two parts? correct?

Yes.  The pier has been in place for a few months now.  The slab will be poured around the pier, with some foam placed around the pier while pouring to leave a small gap.

 

49089796563_e7ab988a41_c.jpg_CFA9467-1 by Colo CJ, on Flickr


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#73 Tom K

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Posted 20 November 2019 - 08:10 AM

Most impressive!   Well done!



#74 Acer

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Posted 20 November 2019 - 06:47 PM

Today I finished the base, as much as I can until I move it to the house.

 

I finished installing all the sheet metal, then I built the door and installed the locking system.

It was a little bit of work compared to a normal door, since I had to make allowances for the corrugated metal, especially around the lock.  

It is finished now though.  Tomorrow I am going to make the form for the slab (It will be a 9' round slab to fit the 8' dome).  I might pour it tomorrow if the weather cooperates.

 

All these photos show the base upside down, since it is easier to install the corrugated metal this way.

 

49097021478_81e278d64f_c.jpgDSCF2080-1 by Colo CJ, on Flickr

 

49097728087_ba3e2f849a_c.jpgDSCF2078-1 by Colo CJ, on Flickr

 

Here is the inside showing the lock.  It is installed on built up 2x4 that is bolted to the door frame with 4" heavy screws.

 

49097530461_75e7a54dfd_c.jpgDSCF2083-1 by Colo CJ, on Flickr


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#75 TxStars

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Posted 21 November 2019 - 02:23 PM

Depending on how much rain you get you might want the slab above grade a couple inches and go 10' round with a slight slope on the outer 1' of the slab.


Edited by TxStars, 21 November 2019 - 02:24 PM.



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