|Project by lanwater||posted 12-14-2011 11:27 PM||10147 views||84 times favorited||62 comments|
A project from Aviad87 inspired me http://lumberjocks.com/projects/55001. He also posted a detailed picture blog that made it some much easier to make one. Thanks Aviad87.
Also thanks to Rance for verifying the angles: http://lumberjocks.com/rance/blog/26130
I used 1/2 inch thick plywood from HomeDepot; really cheap stuff.
I also used 2”1/8 for the sides of the hexagons (20 of them) and pentagons (12 of them).
The real soccer ball is around 1” 7/8
I Set the balde to 36 degrees and rip the ply for the pentagones and then to 30 degrees and rip the hexagones
I then proceeded to glue them up. The ply was a little warpped.
I ended up with 2 sausages
I ripped those 2 sausages into 1/2 thick pieces.
Since I do not have an 80 tooth plywood balde and the ply was of a lower quality I ended up with hairy pieces. Slower feed did not help.
I then made 2 templates out of 1/4 thick MDF from an old furniture back: 1 hexagone and 1 pentagone.
I also Made a small jig to help in cutting the dihedral angle (sideways angles).
Please note that my template are not very accurate. But I aligned the good side that had correct angles on the jig for the cuting of those angles:
20.9 degrees for the hexagone sides and 18.7 for the pentagones. Aviad87 has slightly different angles on his blog and I follow what Rance pulled out and which I saw as well here: http://www.coolmath.com/reference/polyhedra-truncated-icosahedron.html
Once all the pieces were cut, it was time to glue up.
I softened all the sides with an orbital sander and sanded all the glue squize out using adhesive back sand paper on a flat stick.
I finish with 1 coat of zinser sanding sealer (2 pound cut shellac).
I am not finishing any further at this time. Maybe one day I will go back (if I keep it), sand further and appliy some poly.
I find out that binder clips work best for the clamping. Unfortunately I did not have many of them.
It was a fun project overall.
As always comments good or bad are welcome. Thanks for looking!
-- Abbas, Castro Valley, CA