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BurningMan2002:TheDome
WhatamI,nuts?
I'mdoingit.Takingtheplunge.Icame,Isaw,Iwanted,I'mbuilding.
IhavedecidedtobuildageodomeforBurningMan2002.ThisisgoingtofunctionasachillspaceforthegroupIamtravelingwiththisyear,TheIslandofBig
Bang.Yes,it'satimetraveltheme.Butmoretothepoint,theyneededadome,Ineededtobuildone.Nextyear,I'lleitheruseitagainwithBigBang,orIcouldtake
ittoanothergroup,ortakeitonmyown,butmeanwhile,thisisthetestyear.Andtheassemblyyear.
Iamchronicallingmyeffortsbelow,completewithphotos.HomageisgiventoJeff,agoodguywhobuiltthissamedomebeforeme,whichgavemeconfidencein
thespecs,andofcourse,maximumpropstoTaraatDesertDomes.com,whosehandyonlinedomecalulatorandinfopageshavehelpedcountlessburnerscreatetheir
structures.Thosewhodidn'tmajorinmathatCalTech,atleast.
Andspeakingofspecs,heretheyare:
Iambuildinga12'radius,3frequency5/8GeoDomefrom3/4"EMTconduit.

Again,thankstoDesertDomes.comforgraciouslyallowingmetousehergraphics.BasedonsomeleadsTaralentme,IhopetogeneratesomeMayarendered
domestomakethingseveneasiertoseeandunderstandinthenottoodistantfuture.
IfyouhaveaVRMLplugin,youcanseea3DviewofasimilardomeatBobCrispen'sVRMLDomessite.Greatinfothereontheunderlyingmath,buthissite
doesn'tshowany5/8'sdomes,soit'snotanexactmatchtoourworkhere.
Lotsbelowforyouramusement.TheguffawswillhavetowaituntilIhaveareallyinterestinginjurytoshow.Meanwhile,choosefrom:
DomeMath
Materials
ConstructionDiary
Photos

Math
PertheDomeCalulator,theinitialmaterialsbreakdownatfora12'radiusdomeis:
StrutA=30pieces4.183'long(4'2.20")
StrutB=55pieces4.842'long(4'10.08")
StrutC=80pieces4.948'long(4'11.40")
4wayconnectors15
5wayconnectors6
6wayconnectors40
=61boltsneeded(61connectionstotal)
Figure1.5"(0.125')extralengthneededforeachstruttoallow.75"fromend(oneachside)tocenterpointofdrilledhole
StrutA=30pieces4.308'long(4'3.72")
StrutB=55pieces4.967'long(4'11.64")
StrutC=80pieces5.073'long(5'0.88")
Roundingupforinitialcutting,Ineed:
30x4'4"sections
55x5'sections,and
80x5'1"sections.
Figurecuttingbladeis1/8"thick.
Figure10'sectionofconduitcuttogiveexact4'113/4"sectionsand"closeenough"5'something"sectionswouldsuffice.
Thisiswhenrealitystrikes.No.Turnsoutthiswon'twork.It'sclose,butnotquiteprecise,andprecisionisneededforadomethissizethatgoesupwithouta
struggle.So.
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11.93'RadiusDome(I'mstillgoingtorefertoitasa12'dome,ofcourse):
StrutA=30pieces4.159'long(4'1.92")
StrutB=55pieces4.814'long(4'9.77")
StrutC=80pieces4.920'long(4'11.04")
Roundingupforinitialcutting,Ineed:
30x4'2"
55x4'10"
80x4'11"
So,10sectionsofconduityield10xCstrutsand10xBstruts
Continueinbatchesof10untilIhaveall55(bettermakeit57forextras)sectionsof"B"plus57sectionsof"C",thenshifttocutting"A"and"C"strutsfromeach
section.
Makefirstbatchofcuts(55ofthem)at4'10"yields:
one4'10"section(only1/4"toolong)and
one4'11.75"section(3/4"toolong)
Nogood.Bettermakefirstbatchofcutsat4'11"Theextra0.04"canbesoakedupinashorterflatsectionfortheboltwithnoproblem.
Thatleavesmewithremaindersectionsat5'.75"Mayaswelllopoff13/4"fromtheendandendupwith2x"C"sectionsfromeach10'lengthofconduit.Thatgives
methe80sectionsIneedoutofthefirst40piecesofconduit.Extrasandtheremaining85sections(A'sandB's)cancomefromthenextbatch,alsowith2cutsper
conduitpiece.
Andthat'swhatIdid.Theresult:
Pardonmyfrench.F*%$.F*%$.F*%$.F*%$.
Aftercurttingthepieces,Icheckedmyfigurestogetreadytodosomesquishingwhen,tomyhorror,IdiscoveredIseemedtohaveforgottensomethingimportantin
mycalculations:Theadditionallength(1.5")tobeaddedtoeachstruttoaccountforthescrewtoscrewmeasurements.
1.5"=.125'
(forexample)4.920'+.125'=5.05feet
Result:Ishouldhavecutthedamnthingsexactlyinhalfformy"C"struts.Asthingsstandfornow,allofmystrutsareexactly1.5"tooshortforthe11.93'dome.
F*%$.Thetrickistorunthedomecalulatorandthenadd.125'(1.5")toeachofthelengthswhenyougetreadytocutthedamnthings.That'swhatI*should*have
done.
Ok,whatcanwedo?DidIjustwasteover$200worthofconduit,nottomentionmytimeandenergy?Let'sconsultthedomecalulator.Iwillworkbackwardsfrom
whatIhaveandseeifIcanfindacombothatworksright.It'sonly1.5"offeach,consistently,right?
SoIhave:
StrutA=30pieces4.159'long(4'1.92")
StrutB=55pieces4.814'long(4'9.77")
StrutC=80pieces4.920'long(4'11.04")
Subtracting.125'fromeachmeasurement,IseeIneedtofindadomewherestrut"C"measures4.80',strut"B"measures4.69'andstrut"C"measures4.04'.Let's
playwithfigures...
Woohoo!Allisnotlost!
Turnsoutan11.62'radiusdome(11'7.44")resultsinthefollowing:
Centerpointmeasurements:
StrutA=30pieces4.050'long(4'1/2")
StrutB=55pieces4.689'long(4'81/4")
StrutC=80pieces4.792'long(4'91/2")
ThoseseemcloseenoughtowhatIhave/needtome!LookslikeI'mgoingtolosealmost6"ofmydome.Thatsucks.Buthey,justover11andahalffeetradiusstill
seemsprettydamnclosetoa12'radiusdometome.Thatwasclose,though.Liveandlearn,Iguess.:(
Well,InowhavethemeasurementsIneedtoworktowardstomakemydrillingandsquishingtemplates.

Materials
StuffIboughtforthisproject:
3/4"EMTConduit("thinwallconduit"):$2.26athomedepotper10'section,90pieces($220,withtax).
WorkBench:Youreallygottahaveone.Ifoundanice,cheap(butfunctional)oneatHomeDepotforabout$60.5'x2'workingsurface,andheavyenoughand
sturdyenoughtomountabenchviceto.Thisprojectisgoingtorequiremorethanthestepsfromthekitchentothebackyard!
Black&DeckerHobbyBenchandProjectVise:Thiswasinvaluable.Ialmostdidn'tgetone,sinceIhadthebenchlistedabove,butwhenInoticedthe"vise"could
rotateandworkverticallyaswell,thevisionsIhadofconduitneatlyheldinplaceinaflatlinewereirresistable.Turnsouttheworkingsurfaceflexesinthemiddle
toomuchtoholdthemiddlestuffstronglyenoughtosawthewayIneededto,butIwasstillgladtohaveit.($77atHomeDepot)
BenchVise:$50atOsh.I'llneedthisforbendingtheconduit,onceIgettothatpoint.
1tonArborPress:$38atHarborFreight.I'llneedthisforsquishingtheendsoftheconduit
1/3hpDrillPress:$40(slightlyused,orIwouldhavepaid$80atHarborFreightfortheexactsameone).Usedfordrillingtheboltholesintheconduit.Duh.
7x6.5"Metalcutoffbladesforthecircularsaw:$1.83eachatHomeDepot.Getthebiggeronesifyoursawwilltakethem.Also,IboughtthecheapNortonblades
becauseHDonlycarriedthatbrandforthesmaller6.5"saws.I'mtoldthebetter,slightlypricieroncesareworthitbecausetheylastlonger,buttheyonlycamein
7.25"...toobigformysaw.:(
two18"slidingbarclamps(byJorgensen):$25andchangeforthepairatHomeDepot.Iusedthesetohold2x4'sinplaceforthejigIriggedupforsquishingand
drillingthestruts.
Cobalthighspeedmetalcuttingdrillbit(3/8"):$10atOsh,plus$3.50forcuttingoil.
Totalspentsofar:$560,withtax
StuffIhad:
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Variousclamps:IhaveseveraloftheneatwoodonesfromJorgensen,thesmallerandlargersizesboth,andusedallofthemextensively.Ialsohaveusedavariable
bandclamp,whichisanylonwebbeltthattightensalooparoundanything,thekindyoucanuseonpictureframesandsuch,formakingtheconduitsandwich
(whichkeptthemtogetherasonepieceduringcutting).IcouldreallyuseanotherbutapparentlyHomeDepotdoesn'tcarrythemanymore.:(I'llkeepmyeyes
open...
CircularSaw:Black&DeckerWoodHawk.Sofarthishasworkedfine.Iloveitasawoodsaw,butIwish(a)itwasmetal,duetothespaks,and(b)itwasnotso
niceandcompact,usingonlythe6.5"sawbladessincethe7.25"bladeswouldcutconduitfasterandcooler.WorksgreatonwoodIjusthopeitsurvivescuttingall
thismetal...
14'Accordianstyleladder:I'llusethistoassemblethefinisheddome,butitalsoworkedgreatduringthecuttingphaseasasawhorsewhenIputisinthe"M"mode
toemulateadoublesawhorse.JusttherightheightfortheBlack&Deckerhobbybench.IlaidthelonglenghtsofconduitonittokeepitallflatwhileIcut.I'll
probablyendupneedinganother,longeroneforthefinalassemblystages,cuzIdon'tthinkthisoneistallenoughfortheveryhighestbits.
Variouswoodsaws,scrapwood,tapemeasures,etc.
StuffIstillneedtobuy:
17'accordianladder:Thiscanwaituntiltheendoftheproject,asmyexistingladderswilldountilI'mreadytoactuallyfullyassemblethesucker.$170atHome
Depot,unlessIcanborrowonesomewhere
Nuts,boltsandwashers:Upnext.Oneboxof100coarsethread3/8"Hexbolts,2.5"long,zinccoatedforrustprevention,oneboxof100nuts,oneboxof3/8"flat
cutwashers.Shouldberoughly$35,total,atHomeDepot.IshouldalsohitHarborFreightandpickupabunchofcheapsocketwrenchesintheappropriatesizeso
thatmultiplepeoplecanassistwiththeassemblyatonce.
Spraypaint:3cansin3differnetcolors,forcolorcodingthevariousstrutlengths.Makesassemblyaloteasier.AlsohelpspreventrustintheexposedendswhereI
havecutanddrilledthroughthegalvanizedcoating.NopointinbuyingthemuntilIhavefinisheddrilling,though.Update:Iwentwitha$2.50packofelectrical
tapeinmultiplecolorsinstead.We'llseehowitholdsup...ifnotsowell,I'llpaintthemfornextyear.
Arborpressplate:TurnsoutIdon'tneedthisafterall.ButImightwanttogetonesomeday.
Trailer:GottagetthisdometoBurningMan,don'tI?!?Estimate$300400.
Tarps:Thiswillwaituntil(a)Ihavethemoney,and(b)they'reonsale.Notmuchpointinadomewithoutaroofunlesswe'regoingThunderDome,andthisisn't
strongenoughforthatmanypeopletoclimb.Theheavyduty,silveryreflectivetarpswillformtheskinforthisdome.2tarps:one20x30(tobecutinto310x20
strips,$55regprice)andone40x30(tobecutintoone10x30andone30x30tarp,$100regprice).Basically,the10xwhateverstriptarpswillgoaroundthebase,
andthelarge30x30tarpwillgooverthetop.It'llallbeheldinplacewithropesandperhapssometarpclips.
Turbinevents:Again,nopointuntilfinalassembly,butthesewillletthehot(Imean,"HOT!!!")airoutoftheroofduringthoseblazinghotdaysontheplaya.And
shoulditrain,they'reprettyweatherproof,beingdesignedforroofsandall.About$25eachatHomeDepot.

ConstructionDiary
Sunday:6/2/02
Therealworkbegins.IfinallyhadcollectedallthetoolsIthoughtIwouldneed,enoughrawmaterialstostart(thatis,twenty10'sectionsof3/4"EMTconduit)and
hadworkedouttheactualmathsoIknewexactlywhatIneededtocuteachpieceofconduitdownto.
Ihavereadthehorrorstoriesabouthowlongittooktocutallthedamnconduitsectionsneededforadecentsizedome.Ihadaplantodrasticallycutthattime
down,however.Theplanwastolayouttheconduitinalongrow,andjustrunthecircularsawoveritwithametalcutoffbladetocutmanypiecesingreatswaths.I
wasevenmorekeenonthiswhenIgotthehobbybench.Realitywasamorelimitedapplicationofthattheory.Theproblem,ofcourse,isthattheconduitdoesn't
reallylikebeingcut,andtriestosquirmoutoftheway.*g*Tomakealongstoryshort,Iendedupdoingitingroupsof5.Stillquitefastcomparedtodoingitoneat
atime,I'dimage.
Ihadissues,onthefirstcut,withthepipeswantingtomovearound.Isolvedtheproblemwithacombinationofatheverticalvisemodeofmyhobbybench,some
variousclamps,andacoupleofpiecesofscrapwood.Imadeaconduitsandwichwiththescrapwood,andthenbasicallyclampedthehelloutofeverything.That
seemedtoholdthingssecurelyenoughtocutfivepiecesatatime.Imighthavebeenabletogolongeranddomorepiecesatonce,butfrankly,Iwasworriedformy
circularsaw.IhaveaBlack&DeckerWoodHawk,whichisgreatforwood,butithasaplasticbody.Asyoumaybeabletoseefromthepictures,themetalcutoff
bladeproduced*huge*showersofsparks.Trustme,onlysomeofthemshowinthepictures.Iwasseriouslyworriedabouttheheatmeltingtheplasticpartsofmy
saw,andthesparkssettingthings(includingme!)onfire.Evenwithabettersaw,cuttingmuchmorethan5atoncewouldprobablycauseissueswithheat,possibly
burningtheconduit,anddefinitelyshorteningthelifeofthecutoffblades.Twothingstokeepinmind:1)Iwasverygreatfulformynewhaircut(thatistosay,
almostnone).IfIhadstillhadlonghairthatwasn'tseriouslycontrolled,I'dhavebeenpanicingaboutbeingsetonfire.Asitwas,Iwasalittleconcernedformy
pantsandshirt,butsofarthey'vebeenfine.2)Iwearglasses.AssuchItendtoscoffatwarningsaboutwearingsafetygoggles.Wearthem.Youhavetostickyour
faceprettydamnclosetothesourceofthosesparkstoseewherethesawwantstogo(andcoaxitintothedirectionYOUwantittogo).Irepeat:Wearsafety
goggles.
Sofar,onthisfirstrealdayofwork,Ihaveaccomplishedthefollowing:1)IactuallyWorkedoutallthemathcalculations(withthehelpofTara'sDomeCalculator,
ofcourse)towhereIactuallyunderstandthem,whichissomethingIhadhopedtoavoid.Justdoit.Youneedtoreallygetwhatyou'redoingwiththeenddrill
allowances,etc.2)IhaveamethodologyforcuttingconduitthatshouldgetmethroughallthecutsI'llneedthroughtherestofthisproject.3)Ihaveproduced38of
the80"C"strutsIneed.Itwouldhavebeen40,butoneofthepiecesofconduitIboughtinabundlewasdentedsobaditwasn'tstraightanymore,andconsidering
thisisastructuralmember(asareallthesections),IthoughtitbestthatInotuseadamagedbeam.I'llreturnitwhenIgotogetthenextbatches.(Purchasingthe
conduitinbundlesof10makesthingseasieronthepocketbookthanbuyingitallatonce,andsinceI'mgettingitatHomeDepot,it'snotlikethereisavolume
discount.)Iactuallymadeallthecuts,includingworkingoutthebestwaytodoit,inabout2hours.TherestofthedaywasrunningbackandforthtoHomeDepot
forvariousthingsandthemath.IsuspectI'llwhipthroughthenext20sectionsofconduit(21withthereplacementpiece,Iguess)infarlesstime,producingthe
next40Cstruts.AfterthatI'llstartdoingtheAandBstruts.NowIhavetoactuallyfindoutifIreallyneedapressplateforthearborpressorifIcangetawaywith
usingitasitcame...
I'mgoingtokeeparunningtotalofhowmuchtimeI'mputtingintothis.Isuspectitwillbelargelyestimated,butI'mgoingtotrytofigureouthowmuchtimeI'm
actuallyspendingdoingwork,definedasputtingtoolstorawmaterials,asopposedtomessingaround,tryingtofigureoutthebestwaytodostuff,runningmath
figuresthroughthedomecalculator,runningerrandstoHomeDepotforsupplies,updatingthispage)etc.
HANDSONTIMESPENT:2Hours
EXPERIMENTATION,ERRANDS,ORGANIZATIONTIMESPENT:2Hours
RUNNINGTOTAL:2Hourshandson,2Hoursother
Saturday:6/22/02
DamncomputercrashatemyupdatebeforeIhitsave.Ok.Shortversion:Fairesdone.WorkResumes.Latestart.Bought71sectionsofconduitshouldbeallIneed.
BythetimeIgotmylatestart,setupandgotowork,Ionlycut12morebeforedark.(IthrewonemoresectionintotheonebatchIworkedwithtomakeupforthe
bentonefromlasttime.)Nowupto50"C"piecescompleted.
HANDSONTIMESPENT:1/2Hour
EXPERIMENTATION,ERRANDS,ORGANIZATIONTIMESPENT:1.5Hours
RUNNINGTOTAL:2.5Hourshandson,3.5Hoursother
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Latestart,asusual,butnotasbad.Inonehalfhourstretch,sinceIwasmostlysetupstillfromworkingyesterday,Icut16moresectionsofconduitinthreecutting
sessions(2cutspersession).Ifiguredoutaslightlybetterwayofworkingtheclampsandsuch,soIbasicallymeansurebothcutsatonce(4'11"fromeachend),run
thedrillonce,letthefinishedsectionsfallaway,andtherunthedrillagainthroughthestillclampedothersections,lettingthe1.5"(roughly)remnantsfallaway,
beforeIhavetopulleverythingoutandresettheclamps,measure,etc.(IpromiseI'llphotographitlater)SoIfinished32moresectionstoday,bringingmetoa
grandtotalof82"C"lengthsections.Thisgivesmetwospares.I'msureI'llneedmore,butIwanttocutallthestuffIneedbeforeIstartgoingcrazywiththespares.
Thatwasthebigpush,ofcourse,theC's.I'mjustabouthalfwaydone.Woohoo!
Oh,pointofinterest:Ifinallyhadtochangethecutoffbladeonmycircularsawwhilefinishingthelastcuts.SoIwasabletomakeapprox70polesontheonecutoff
wheel.Atthatrate,oneortwomoreandIshouldbeabletofinishthisproject.Consideringthey're$1.88,that'sprettygood,IMO.WhatsucksisatriptoHome
Depotmightspelldoomforfinishingallthecuttingtoday.We'llsee.PerhapsI'llpickupsomethingtocleanupthecutendswhileI'mthere,likeagrindingwheelI
canmountonmydrillorsomethinglikethat.Therearesomeprettysharpsendsonthosepuppies.Hmm,perhapssomeboltstotiedownthearborpressmightbein
order,aswell...
Annoyingly,I'mgoingtohavetostartlabelingthesections.BecausenextupIgettostartcuttingA'sandB's,andIjustknowthey'llallgetmixedtogether.The
currentplanistojusttageachpolewithasharpieandwritea"C"oneachend.Still,I'mproudIgotallthosecutsdoneinahalfhour.Timetostopmuckingabouton
thecomputer(ahh...airconditioning...)andgetbacktowork.
Let'ssee:
30x4'2"
55x4'10"
80x4'11"
Ihavethe804'11""C"lengthpolesnow,soontothe55B'sIneedat4'10".Backinaflash!
Well,thatwasashort15minutes,eh?IsurewishIknewhowonearthImanagedtogothroughanentirecutoffwheelthatfast.Perhapsthefirstonewasafluke?
Maybethissecondonewasextrapoorlymade?Ihavenoidea.ButlookslikeI'mheadedbacktoHomedepotearly...IthinkI'llgrababout5...
AnotherhourfrommylifegoneduetoaHomeDepotrun.ButIhaveenoughcutoffbladestofinishthejob,Ithink.Ihavecarriageboltsforthearborpress.AndI
decidedtopassonthe$406"benchgrindingwheelandjustborrowmyfather'sforfree,onceIgettothatpoint.
Iresumedworkat4:15.It'snow5:40andI'vefinished57B's,sothat'sonemoredown(2arespares,ofcourse.)Ihaveenoughconduitleftfor42moresections(21
tubes),andIonlyNEED32,soIshouldbeprettygoodshapeshortly.I'vegonethroughtwomorecutoffs,soIhavewhat'sleftofthisfairlynewone,andtwo
remaining.I'mconfidentthatwillcoverme.Ok,backoutfor324'2"Asections...
7:00.Alldone.Andthatincludescleanupandstartingtoprepthearborpressforattachmenttomyworkbench.So...anhour?Nah.Morelike45minutesofactual
handsonwork.
Imountedthearborpresstotheworkbench,andtestedapieceofscrap.Ahhh,squishygoodness.Thisshouldbenoproblem,onceImakesomesortoftemplate.
Pointofinterest:IhavebeentoldIneedsomesortofthicksteelpressplateforthearborpress.Icanseehowthatmightbethecasewithlargerdiameterstock,but
thisstuffissmallenoughtheplatethethingcamewithseemstoworkfine.
Remainingtodo:Maketemplateandsquishalltheends.Onceeverythingissquished,thearborpressgoesintothegaragetobereplacedbythedrillpressforsome
holeyfun.Thenanothertemplatefordrillingthethreesizepoles.Yetanothertemplateforthebending.Andthentheactualassembly!Woohoo!Thenicething
aboutthesenextpartsistheyarethesortofthingthatdoesn'trequirequitesomuchsetup.SoIshouldbeabletodoafeweverynightinsteadofneedingtodothem
allinonebigbatch,likethecutting.Thecuttingrequireddaylightandlotsofstretchesoftime,becausetherewastoomuchsetup.Ican'twaittodomore!
AfterputzingaboutforanhourwithmathafterIrealizedmymistakewiththestrutlengthsvs.centerpoint/bolttoboltmeasurements,andfiguringtheupdated
measurementsIneededforthesquishingpart,Idecidedtocutasmallpieceofscrapwoodtouseasastopinthethroatofthearborpress.ThatwayIjuststickthe
strutunderthepressrod,goingbackinuntilithitsthewoodandstops.Presto!Perfectsquisheseverytime.Itestedthisafewtimeswithsomeoftheremnantbitsof
conduitbeforetryingitwiththerealstruts.
Itook2piecesof2x4stackedontopofeachotherjusttosupportthestrutwhileitwasbeingsquished.Itjustmadethingsalittleesier,Ithink,becauseitmadeita
fairlyflatrunratherthanhavingithangoutofthemouthofthepress.IshouldnotethatIhavereadthatitisimportanttosquishtheconduitwiththecenterweldin
themiddleoftheswuishedsection,asapparentlyitcansplitifitisonanend.SoIdidmybesttofindtheweldandputitinthemiddle.Itwasdark,however,and
sometimeshardtotell,soImayormaynothavebeensuccessfulincorrectlyidentifyingtheweld.Regardless,Ihavenothadanyproblemswithsplittingsofar.
(*Note:Ihavesincebeentoldthattheweldshouldactuallybeata45degreeangletopreventsplitting,notrightinthemiddle,whereIhavebeendoingit.BitIhave
yettosplitasinglepiece.Justlucky?Whoknows.)Sotonight,inalittleunderanhour,Isquishedoneendofall32ofmy"A"struts.I'llsquishtheendsofallthe
otherstrutsthroughouttheweek.
Twothingstonoteaboutsquishingwiththisarborpress.First,whileit'snotteriiblydifficult,ittookalittlebitofmuscle,andputtingsomeweightontothebar,to
squishthepoles.AsImentioned,however,itwasn'tthatbad.Thiswasdefinitelythemostphysicallydemandingpartofthisprojectsofar,however,withthe
possibleexceptionofschleppingthe10'longbundlesof10conduitsections(fromHomeDepot)frommycartothebackyard.Thesecondthingtomentionisit's
fairlycriticalthattheflatendsbeingalongthesameplane.Itwouldn'tdotohaveatwistfromoneendtothenext...soIwillneedtorigajigofsomesort(perhaps
justaslotinapieceofscrapwood)toensurethesquishedendslineupperfectly.
HANDSONTIMESPENT:4Hours
EXPERIMENTATION,ERRANDS,ORGANIZATIONTIMESPENT:4Hours
RUNNINGTOTAL:6.5Hourshandson,7.5Hoursother
Monday:6/24/02
Moresquishing.AndmayIsayit'srunningsmoothly?Itonlytookanhourandahalftosquishall139remainingends(57B'sand82C's).ItookJeff'sadviceand
usedapieceoflongerconduitscrap(thelongonesinthepicture...about20")asacheaterbartomakesquishingeasier.Ijustremovedtherubberendcap,slidthe
barover,andwrappedabitoftapearoundtheendtoholditinplace.Ugly,butitmadesquishingMUCHeasier.That'showIwasabletogothroughitsofast.
Ofcourse,I'veonlysquishedoneendofeachstrut,andIstillneedtosquishtheotherend.Tomorrow,I'mgoingtofigureoutwhatsortofajigIwanttomaketo
ensurethesquishesareinthesameplane.I'mthinkingI'llusemyrouteroreventheskilsawandcutalonggroveina2x4thattheconduitcansitin.Theflatflange
onthesquishedendwillkeepitperfectlyflat,evenallowingforslightvariancesintheangleoftheflange,whileIsquishtheotherend.AttherateI'msquishing,
dependingonhowlongittakesmetocutthegroove(man,IwishIhadatablesaw!),Ishouldbeabletofinishsquishingeverythingtomorrowevening,andthenI'll
bereadyfordrilling!Woohoo!
HANDSONTIMESPENT:1.5Hours
EXPERIMENTATION,ERRANDS,ORGANIZATIONTIMESPENT:.25Hours
RUNNINGTOTAL:8.0Hourshandson,7.75Hoursother
Wednesday:6/26/02
Finishedsquishing.Ifiguredoutajig,butdecidedIneededacouplemoreclamps,withasmallfootprintandlargerthroatsize,thanthewoodJorgensenonesIhad,
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soIpickeduptwo18"clamps(ironically,alsobyJorgensen)atHomeDepot,ofcourse.$25forthepair.pickedupMadeajigofsortsbycuttingaslotintoapiece
ofscrapandmountingonthefarend.AllIhadtodowasslotthefinishedendintoplace,pullthestrutuptothestopblock,andsquish!Ifinishedthewholelotin
about2.5hours,butI'dguessittookagoodhouroffutzingandexperimentingbeforeIgotmysystemdown.Ironically,thelast32"A"strutsprovedthemost
difficult...thejigIhadmadedidnotgoshortenough,sothestrutwouldn'treachtheslotatthefarend!Icobbledtogetherahackjobandgotitdone,butlessons
werelearned.
Inoticed,whensquishingthesecondside,thatbecausethebarcouldnotbendupasIhadallowedittoonthefirstsquish,thesecondsquish"profile",forlackofa
betterword,seemedtohaveonesidesquishedfartherupthantheother.Thisisbecauseofthedifferencebetweentheroundbaseplatethatcamewiththearborpress
andthesquishingramroditself.(See"Profile"picbelow,alsocomparethedrilledC'stothedrilledA's,afewpicslater).IsuspectthisisbecauseIdidn'tbotherto
purchasepressplatesforthearborpress.Hopefullythiswon'tcauseanyproblems,butIwillattempttofaceallthepolesinonedirection,forconsistency'ssake.All
ofthe"longer"squishedsidescanthenfaceintothedomeoroutofit,dependingonwhatdecisionImakewhenitcomestimeforassembly.We'llsee...
HANDSONTIMESPENT:2.5Hours
EXPERIMENTATION,ERRANDS,ORGANIZATIONTIMESPENT:1Hour
RUNNINGTOTAL:10.5Hourshandson,8.75Hoursother
Saturday:6/29/02
Afterscoutingoutafewdifferentstoresduringtheweek,andtalkingtovarioussalespeople,IdeterminedthatCobaltdrillbitsarebestsuitedfordrillinglotsof
metal.Thesuckersaredesignedtodrillthrougharmorplate,even!Alsocritical,whencuttingmetal,isusingcuttingoil.SoofftoOsh,andI'mreadytojuryrigyet
anotherjig.
Imovedthearborpressoutofthewayandusedtheboltstomountthedrillpresssecurelytomyworkbench.Somestacked2x4's,screwedtogethertomakethem
staystacked,anda1x4forthejigitself,andI'mreadytogo.Iusedthetwobarclampstokeepeverythinginplace.Iusedtwoofthewoodclampsattheendtomake
achannelforthestrutend,andtwoscrewsinthemiddleoftheboardseemtobedoinganicejobofslottingthestrutsintoplacequickly,easily,andaccurately.
Finallydrilling.Idecidedtoeyeballtheholesonthefirstend.WhenIsetupthejigforthesecondside,themoreprecisemeasurementwillfallintoplace.You'llsee
whereIdrilledthefirstholeinpicturesbelow(basicallyabout1/4"fromtheend,alongtheinsideedgeofthesquarethearborpressmadewhensquishingitflat).
NotethatIplacedadropofcuttingoilonendendbeforedrilling,inanattempttopreservemybitandavoidtheneedforsharpeningit.Thatdropalsomakesa
dandyaimingdotwhenmanoeuveringthestrutsintoplace.AlsonotethatIdidn'thavethestrutsstrappedintoplace...Ibasicallyheldthemdownwithonehand
whileIloweredthedrillwiththeother.Thisallowedmetomakesmalladjustmentstotheangle,etc.,asthebitstartedbitingintothemetal.
Becarefuldrilling,andnotefarfaryou'regoingthrough.Goslow...thebithadatendencytobitoffmorethanitcouldchewonsomeoccasionswhenIgotlax.This
causedthebittoslamintometaltoothicktocutthrough,whichbroughtthewholethingtoascreechinghalt.Onceortwiceitevencausedthestruttogetdrawnup
thebitveryforcefully,jerkingitrightoutofthehandholdingitdown,even.Ihadtokillthedrillpressandmanuallyspinthebitbackwardstowalkthepoleoffthe
bit,andstartmoreslowly.Ifounditbesttowatchcarefullywhereyouare,andthen,whenyougetclosetopunchingthrough,backitofffrequentlytocheck
progress,andapplylessandlesspressureuntilitfinallygentlypushedthroughtheotherside.
It'sgoingatareasonablespeed,Iguess.Lotsofinterruptions,soit'shardtotrack,butI'dsayIdid40inthefirst1.5hrsandlater,theremaining42"C"strutsinone
hour.That'sonlyoneend,ofcourse...aswiththesquishing,Iplantodrilloneendofeachfirstbeforebotheringwiththejigfortheprecisionhole.
Onetiplearned:Wearlongpantsandbootswhendrillingmetal.Themetalflash(thinksawdust)is(a)hot,(b)sharp,and(c)likelytogoflyingoutrightatyou...or
endupINthesidesofyourshoesifyou'rewearingtopsiderswithoutsocks!OnceI'mdonewithallthedrilling,onbothsides,I'llneedtouseatoolofsomesortto
cleanthesharpflashoutoftheholes,inadditiontocleaningthesharpbitsofftheendswiththebenchgrinder.
HANDSONTIMESPENT:2.5Hours
EXPERIMENTATION,ERRANDS,ORGANIZATIONTIMESPENT:1.5Hours
RUNNINGTOTAL:13.0Hourshandson,10.25Hoursother
Sunday:6/30/02
Finishedupthedrillingofoneend.Ascouldbepredicted,ittookjustover2hourstodrilltheremaining89sections(32A'sand57B's),withminimaltimewasted,
becauseeverythingwasstillsetupfromdrillingtheC's.Boringentry,Iknow,butitwasallstraightforward,withnosurprises.Gettingsoclose,though!!!
WOOHOO!!!
Bytheway,Iapologizeforsomanypicturesoftheendsofsemifinishedpoles.I'msure,readingthisinfoallinonesitting,longafterconstructionceases,theyseem
highlyrepetitive.However,youhavenoideahowsatisyingitistotakethatpicture,indicatingonemorecompletedsteptowardsthegoal.Or,ifyouhavebuilta
domebefore,orifyouarefollowingtheselogsinanefforttobuildyourowndome,you(will)understandcompletely.
That'sitforthisinstallment.MoretocomeasIcompletemorebits!
HANDSONTIMESPENT:2.0Hours
EXPERIMENTATION,ERRANDS,ORGANIZATIONTIMESPENT:.25Hours
RUNNINGTOTAL:15.0Hourshandson,10.5Hoursother
Friday:7/5/02
Drillingalldonenow,finally.IfIneverseeanothersquishedpolewaitingtobedrilled,it'llbetoosoon.Thelast30orsoIcouldtellthedrillbitwasgettingtothe
pointofneedingsharpening,butalittleextrapressureandIwasabletofinishoutthebatch.Handy,becauseIdon'thaveabitsharpenerandreallydon'tfeellike
buyingonejustforthisproject.I'msuregladIboughtthesuperdupercobaltdrillbit,however...anylesserbitswouldnothavefinishedthisjobwithoutneeding
sharpening.Asitis,drillingnearly400holesthroughsteelpipebeforeneedingsharpeningisprettydamngood,ifyouaskme.Asidefromthat,however,thelast
holeswentsmoothly...withoneexception,whichI'llgointobelow.
Atanyrate,here'showIdidit.Thefirstholewasfairlynonessential,fromaplacementstandpoint(withoneexceptionthatI'llgointobelow).Thesecondhole,
however,needstobeafixed,precisedistanceforthiswholedomeconcepttoworkout.Thisisrathereasilyaccomplished,howeverbyaboardwithaboltfor
alignment.Itooka1x4andlaiditoutunderthedrillpress,buildingupastandofsortswithscrapwoodsothewholethinglaylevel.ThenIplacedthefirst"C"strut
ontheboard.ImeasuredfromthemidpointofthefirstholetoexactlywhereIneededtodrillthecenterpointofthesecondhole,onthefarend.Youmayrecallthe
centerpointcenterpointmeasurementsareasfollows:A'sare4'1/2",B'sare4'81/4",andC'sare4'91/2".Iplacedthestrutandboardunderthedrillpress,and
loweredthebittotouchthepoletomakesureIwaslineduptoexactlywhereIwantedtodrill.(Seephotosbelow)Imarkedwheretheholewasatthedrilledend,
drilleda3/8"holeinthe1x4,droppeda3"longboltin(withwashers)andlockedthewholethingdownwithanut.NowIhadaboltstickingoutthatIcouldthread
thestrutontothroughtheexistinghole,andtheotherendlinesupattheprecisedistanceunderthedrillpressbitsodrillthenextholeintheexactplaceIneedto
makethecenterpointsaccurate.
AfterfinishingtheCstruts,IrepeatedthemeasuringproceduretotheB'sandA's,drillingnewholesinthe1x4templateatprogressivelycloserspotsforthe
alignmentboltplacement(accordingtothecenterpointmeasurementsforeachstruttype),anddrilledawayquitehappily.Itwasactuallyeasierandfasterthan
drillingtheholesonthefirstside,becausethestrutlinedupsopreciselyandeasilyjustbydroppingitontothebolt.ThetwoscrewsIhadusedduringthedrillingof
theotherendskeptthestrutsperfectlystraightontheboard.Itwasonlyalittletoughtowardstheend,whenthebitwasgettingdull.
Here'stheonethingthatwentwrong:IfIeverdothisagain,IneedtomakecarefulnoteofexactlywhereIdrillthefirsthole,andcheckwherethatholewillforce
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thesecondholetobe.Asyoumayrecallfromabove,Idrilledthefirstholeroughly1/4"fromtheend,figuringthatwastheminimumdistanceIwanteditfromthe
endofthestrut(forstrengthreasons).I'dratherhaveitbealittleclosetothissidethantheother,sinceIcan'taddlengthtothepoleifIwastodrilltoofarinona
slightlyshortpoleanditputstheotherholetooclosetothefaredge.Soundsreasonable,right?Ifonestrutwas1/8"tooshort,Icouldtheoreticallyendupwitha
secondholeneedingtobeplaced1/8"fromthefarend,whichreallyisn'tenoughtogiveenoughmaterialtoproperlyholdabolt.ThisworkedgreatontheA'sand
C's.So...reasonable,yes...exceptwhenyouconsiderthelimitedamountofsquishedsurfaceontheotherside.OntheB's,Iendedupneedingtoplaceholes(on
some,atleast)thatwerehalfontheflatpart,andhalfontotheroundpartofthestrutclearly,anunworkablesituation.Andothershadtheholeplacedallonthe
flat,butfartooclosetothepartwherethepolestartsgoingbacktoround...weneedroomforthewashers,afterall!Tomakealongstoryshort,Iendedupneeding
resquishall57oftheBstruts,addinganother1/2"offlattenedpoletoeach.ThisgavemealltheclearanceIneeded,andfrankly,didn'ttakeallthatlong.Soall's
wellthatendswell.Butitwasn'tasprettyofaresultasitcouldhavebeen,anditmademedomoreworkthanIshouldhavehadto.Lessonlearned:Measurefor
*both*holesonsidesofthepolebeforedrilling,andmakesureyouhaveclearanceforthenutonbothends,andaren'ttooclosetothenonflattenedarea.Ishould
havedrilledrightdownthecenterofthesquishedarea,andIwouldhavebeenfine...about1/8"fartherfromtheendthanIwas.
HANDSONTIMESPENT:4.0Hours
EXPERIMENTATION,ERRANDS,ORGANIZATIONTIMESPENT:1.5Hours
RUNNINGTOTAL:15.0Hourshandson,12.0Hoursother
Saturday&Sunday:7/1314/02
Thelaststep!Irecheckedallmycalculationsjusttomakesure,andrecheckedtheDesertDomessitefortheanglesIneededtobendthetips.TurnsouttheAstruts
needa10degreebend,andtheB'sandC'sbothneed12degrees.Ikickedaroundvariousideasformeasuringandkeepingthecorrectangle,andultimatelyfiguredit
waseasiesttousemybenchvise.Isetupmyviceonthecoverofthetable,androtatedthejaws90degreessotheyfacedtheside.Thisway,whenIinsertedthe
squishedanddrilledendintothejaws,thestrutwassuspendedafewinchesabovethesurfaceofmyworktable.Ithensimplytookaprotractor(actually,Icouldn't
fineminefromhighschoolgeometry,soIfoundoneonlineandprinteditniceandbig!)andmeasureda12degreelinefromtheedgeofthetable,anddrewit(in
pencil)rightontothesurfaceoftheworkbench.Fromthere,Isimplywenttowork:(1)insertstrut,tighten,(2)pushstrutuntilparalleltothe12degreelinebelowit
(seephotos),(3)flipstrutaroundtoinsertotherend,(4)bendasbefore.Repeatuntilallstrutsbent.TheonlydifferenceisontheA's,Ibentthemaweebitless.10
degreesisn'tallthatfarofffrom12degrees,afterall,andthemetalisquitespringy...it'llalllineupjustfine.Thisbendingprocesswentextremelyquickly...perhaps
2hoursforbothsidesofallthestruts.Thiswastheeasieststepofall,I'dhavetosay,eveneasierthanthesquishing(whichtookmoreoomph).
SinceI'mnowdoneworkingthepiecesintoshape,IdecidedifIwasgoingtostartworkingwithandpossiblymixingupthesections,Ishouldlabeltheminsome
way,justtomakeitalleasierwhilethey'rejumbledontheground.IsimplytooksomeelectricaltapeandputacoloredbandaroundeachoftheA's(yellow)and
eachoftheB's(red).I'lllabeltheC'sbeforeIgo,incaseIloseanyoftheotherlabelsinthedust,butthiswillsufficefornow.Itonlytookahalfhourtomarkeach
ofthetwotypeswithalittlebandoftape.Iwascarefulnottoputthebandsallinthesameplace,otherwisethey'dallcometogetherwhenbundledupfortransport
andwouldpreventthemfromlyingalongsideeachothernicely.Overkill?Perhaps.Easy?Definitely.I'mtakingnochanceswiththeplaya...
Nowbeganmyboltdilemmas.Here'stheissue:HomeDepothasapparentlychangedthetypeofboltsitcarries.Thisprojectusesstandardcoarsethreaded2.5"long
3/8"Hexbolts,thekindswithahex"nut"ontheend,asopposedtosmoothtoppedcarriagebolts,whichhavenogoodwaytotightendownfromtheboltend(not
theendthenutgoeson).ThenewhexboltsHomeDepotcarries,however,areonlythreadeduptoabout1"fromthetopofthebolt...inotherwords,theendsare
threaded,butnottheentireshaftofthebolt.Theydidn'tusedtobelikethis,butnow,theonlyboltsofthissizeandshapetheycarrythatarethreadedtheentireshaft
aregalvanizedvs.zinccoated.Problemis,theregularzinccoatedonesare$0.22each,vs.$0.67eachforthegalvanzedones.Ineedaboxof100,anddon'twantto
spend$60onboltswhenitshouldbeabout$20!
Ipickedupafewofeachtypejusttoseehowtheywork,however,anditlookstomeasifthesmoothshaftoneswillworkbarely,butthey'llwork.Thereare
enoughmetalendssandwichedintherethatonceyouaddinthewashers(2ofthem),youclearthesmoothpartandgetintothethreadedsection.Thebottomofthe
domehasfewerpolesateachintersection,butIthinkifwedoubleupthewashersitwillstillbeok.AfterworkI'lltrytofindaHomeDepotthathasthedamnthings
instock(computerinventoryvs.shelfrealityisnotanexactmatchthere,apparently),I'llpickupaboxandthenI'llbereadyforthefullassembly!Yeah,baby!I
usedtheboltsIhadlyingaroundtothrowtogetheracoupleofthesectionsjustforfun,photosarebelow.
Thisconcludestherawmaterialpreparationofthedome,clickinginat30hours(total)onthenose.I'llbetIcoulddooneinlessthanhalfofthattimeifIhadallthe
toolsandmaterialsassembledinoneplaceandatonetime,andhadsomeonehelpingmebydoingsimplethingslikepassingmestruts,etc.Thenextentryyou'llsee
shouldbethefullblownassemblyprocedure.Woohoo!!!
HANDSONTIMESPENT:2.5Hours
EXPERIMENTATION,ERRANDS,ORGANIZATIONTIMESPENT:1.0Hours
RUNNINGTOTAL:17.0Hourshandson,13.0Hoursother
Tuesday,7/16/02
Ifyoubuildit,theywillcome...
Thiscertainlyprovedtrueofmyparents'neighbors.EveryonewantedtoknowwhatonearthIwasbuildinginthefrontlawnonaquietTuesdayeveninginsuburbia.
Shakingheadsabounded.
BUTIDIDIT!
Ibuiltit.Withmyowntwohands(well,mybuddyBillhelpedwtihtheactualassembly,butIdideverythingelsealone).Itwasquitethesatisfactoryconclusionto
whathasbeenalongeffort.Here'showitwent:
9:00:MybuddyBillandIarrive,unloadthecarandgetpsychedup.IlayedoutthepipeinacircleonthegroundattheapproximatesizeIknewI'dneed.Nexttime
I'llusesomestringasacompasstocreateamoreprecisecircleforthatfirstlayer,butthisgotthejobdone.Becareful,though!It'sreallyeasytogetconfusedand
putaBwhereaCshouldbeandsuch,anditsuckstohavetogobackandfixthingslater.Studyingmyconstructiondiagram(seethecenterpictureatthetopofthis
page,obtainedfromTara'sDesertDomessite),Icompletedlayingoutthefirstlevelofpieces.Notetoself(andothers):theinitial(groundlevel)ringhas15sections.
Thisisnotclearfromthegraphic,andifyouforgetitcantakequiteawhiletofigureoutjustwhereandhowtobegin.Thesecondrungalsohas15poles.
9:35:Constructionbegins,withfrequentbreaksforChinesefood.:)
10:30:Leveloneisfinished,andwebeginthesecondlevel.Laddersarealreadybecomingessential.I'mguessingabout45minutestoanhourperlevelisthenorm?
1:30am:Wedidit!Fourhours,starttofinish,withtwopeopleandtwoladders.Nottooshabby,ifyouaskme.Weputthelastpolesthatformtheapex,consistingof
fiveAstrutsinastar,togetheronthegroundandbroughtthemupasonebigpiece,attachingtheendstothestructure.
Ithinkthatmorehandswouldbeoflimitedvalue.Perhapsonemerpersononthegroundasarunner,handingthetwopeopleontheladderpoles,nutsandboltsas
neededwouldbehelpful.Andifyouhadtwomoreladdersandtwomorepeople,youcouldprobablyhavetwocrewsworkingonthingsatonceonoppositesidesof
thedome.Butonceyougettowardsthemiddle,spacewouldgettight.Thatbeingsaid,IthinkI'mgoingtoneedmorepeople(onladders!)whenIputthisthing
togetherwiththeturbinevents.IsuspectI'lldosomethingsimilartoJeff,andconstructtheentiresectiononthegroundwiththeturbineinplaceandliftitupasone
bigsection.That'sgoingtobeheavyenoughthatI'llneedmorethantwosetsofhands,however.
Also,notethatIputthisthingtogetherwithtwo14'accordianstyleladders(mine,andmydad's).Jeff,whobuiltthissamesizeandtypeofdomebeforeme,needed
a17'accordianladdertogetitbuilt.That'sbecauseI'm6'3"tall.Mostpeoplearen't.(Notethat14'and17'referstothelengthoftheladderusedstraightout...inthe
"A"configurationwehadtousesotheywerefreestanding,theyarelessthenhalfoftheirextendedheight,naturally.)I*BARELY*wasabletoreachthehighest
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bitsstandingonmytiptoesontheverytopleveloftheladder.Ialsohaveexcellentbalance,sodon'tsuemeifyourdumbasstriesitandfallsoff!Istrongly
recommendagainstthe14'ladderoptiontoanyonewhoisn'tatleast6'3".Imyselfwouldhavehadamucheasiertimewiththeslightlytallerladder.Theextra1.5'
("A"configurationfortheladder,remember?)wouldhavemadeabigdifferenceatthehighestlevelsandthepeak.
That'sitfornow.NowIhavetogobuysometarpsforthefinalproduct.I'lltakeplentyofpictures,Ipromise!
HANDSONTIMESPENT:4.0Hours
EXPERIMENTATION,ERRANDS,ORGANIZATIONTIMESPENT:.5Hours
RUNNINGTOTAL:21.0Hourshandson,13.5Hoursother

Photos
SessionOne:Weekendof6/02/02

WorkBench

AccordianLadder

WorkMate&CircularSaw

WorkMateVerticalVise

FreshlyCut!

BundledConduit

ClampsGalore

OverallLayout

Oooo...Sparky!

Cuttinglayout

TheFinalCut
38sectionsofhappiness

SessionTwo:Weekendof6/22/02

CuttingTools

Seventysectionsofconduit

ClampingMethodv.2.0

PreppingtheCut

MakingtheCut

57HappyB's

82HappyC's

32HappyA's

171SectionsofDomeonthewall...

That'salotofsteel!

61/2CutoffBlades

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Remnants

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1tonArborPress

Oooo,squishy!

Squishysetup

Midsquish:noteweld
seam

Elbowgrease!

32SquishedA's

Monday:57SquishedB's

Monday:82SquishedC's

SessionThree:Weekendof6/29/02

Arborpresswithcheaterbar

Slottedscrapforstraightstrutends

SquishySetup:TakeTwo

StrutProfile(2ndSquish
end)

Allsquishedupandnowheretogo

DrillingJig:Farend

DrillingJig:Businessend

Preparingtodrill:Note
cuttingoil

Drilling:Hot,sharpmetalflashabounds

Completedhole

82HoleyC's

32HoleyA's

Yay,precise!

Toocloseforcomfort

57HoleyB's
SessionFour:Weekendof7/13/02

4'9.5"ontheCenterpoint
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Alignthebit

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12degreesofseparation

Liningupthevise

Only10degreesfortheA's

Justbendtotheline

LabelledB's

LabelledA's

Finishedpentagonalsection

FinishedHexagonal
section

FinalAssembly

Itbeginswithpiles

Layoutforlayeroneontheground

Completedlayerone

Layertwo

Layerthree

Layerfour

ThePeakAretiptoesonladdersok?

Thelastone!

CallmeJungleJim

Sturdyenoughtoclimb

Bigasahouse!

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