Welcome to Overunity.org.uk
The TPP Project
Here is the original Design by Thomas Trawoger.
To save me explaining all about this one as it has abit of history, please
check out the Pyramid area at
Overunity Forums
http://www.overunity.com/index.php/board,96.0.html
My progress on http://trawoeger-pyramide.info
The Base
My Base is based on the layout below:
I decided to use 20mm MDF as my base plate and so first had to cut a bigger
sheet down to size.
So out with the power saw, Ruler and marker. I marked my first 1000mm mark to be
cut.
I used some straight wall brackets screwed into the wood as my guide to make
sure the line cut dead straight.
Simply measure from your saw blade to the guide to get the correct width and
screw it down.
After cutting one side I then did the same with the other again using the
straight wall brackets as a guide along my next 1000mm line.
This now gave me a perfect 1000mm x 1000mm square and I drew from corner to
corner to get my middle spot.
Next I turned it upside down and marked out where I wanted to place some timbers
to lift it 50mm off the ground, as this will help me when welding as I can use
clamps to hold the metal down square.
I did not have enough timber to do a neat job, but hey it is only there for
support and not to look pretty :)
Ignore pictures below as changed the base bars
The Uprights
Okay have changed now and did the suck and see approach as wasting too much time, will come back to precision later on, but for now I want to get it finished :)
I cut and used 4 uprights at a length of 1000mm based on the design below:
First thing I did was to make sure I had my power hacksaw set to exactly 45 degrees and cut a bit of wood first on a mitre.
I then used this bit of wood to set the angle of the power saw.
Now to set the metal up in the power hacksaw using the V-Blocks.
The finished cut, that I was very pleased with :)
All 4 bars exactly 1000mm on the outside edge and at 45 degrees.
Next to cut the top angle at 60 degrees, either side to make the tip of the pyramid.
First one side
Then the other.
Now to see, if it worked!, yep fits nice and exactly 707mm high :)
Next I cleaned the edges up with a grinder to make sure the weld joints would take.
I layed two of the bars flat down and secured them by clamps and also by screwing in a retainer at the top.
With the metal firmly clamped it was easier to weld, even though I am not a good welder and this is probably the first time in 16 years since I last did any ;D
I cut 4 * 20mmx20mm angle bar to 950mm in length at a 45 degree angle
Then clamped them in.
Welded each corner up keeping the angle flat to the floor.
Repeated this again for the other two uprights and that gave me my two halves of my pyramid.
Next to check they still match up and weld up the tip.
So with the grinder gave it a good old cleanup before setting off doing the joints.
Welded both sides of the tip and ground down again my messy welding.
Back on it's side again, this time too weld in the other two 20mmx20mm angles at 950mm in length.
**** The finished product *****
The corners cleaned up with a grinder.
The tip cleaned up with grinder
Next Step was to drill a hole in the top of the Pyramid.
Then Slide in the 9mm tube and weld in place.
Now cut the tube to 8cm long and give it a good licking of paint.
Onto the plasterboard, lay it out and place each face down, mark and cut. Make sure two sides have the extra 12.5mm either side to overlap.
Glue plasterboard in place and use 3 screws to secure till dry.
3 screws on each side to hold solid while the glue is setting, clamps to keep the sides in place.
4th Panel not fixed yet :) After drying sand down the edges for a perfect shape :) :)
At the Moment Thomas that was running this project has disappeared to sorry to say, yet another one on hold :(
PLEASE NOTE.
Sorry I am not posting the results of my experiments as
this would take too much time.
But when I have something I can shout about and that works 100%, then be assured
I will post an update.
For now this is just a Blog as such of what I am working on.