phase I: conception and construction
I got the idea while looking at this
lamp shade project that it would be neat to make a
polygon
of some sort covered with drawings. Since I'm no artist, I figured I
would
do the construction myself and rope my friends in to doing the art.
I had to figure out a few things: what shape to make, what to make the
frame
out of, how to connect the vertices of the polygon, what paper to use,
and
how to attach the paper to the frame. The first decision was to settle
on
making an icosahedron, a 20-sided polygon. Next up was materials. My
fencing coach
- who is quite handy at building small things - suggested brass rods,
sold
in about 3' lengths at hobby and hardware stores. Since I was looking
to make
an icosahedron about 2' across, this would be perfect. I picked some up
and
started experimenting.
The only real hurdle was figuring out how to fasten the rode to
eachother.
At first I considered cutting the rods so they would form up in exactly
the
right angle and then soldering five together at each vertex, but I
decided
I couldn't get the required precision without better equipment (my
equipment
consisted of my Dremel and... a hammer). I experimented with soldering
ball
bearings at the vertices (i.e. having each of the five rods attach to
the
ball bearing) but this just didn't work and was getting to be a mess.
Finally
I decided to try a method used for making geodesic domes out of steel
tubing:
crimp then ends, drill a hole, and put a pin through five of them. This
worked
perfectly:

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crimped the end and punched a hole
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smoothed out the corners and
rough spots
around the hole
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bent the tab to the appropriate
angle
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I then screwed five of them together to form a vertex
repeated as necessary, and had an icosahedron: