B-9 Construx Page

1) Wood circles cut from ½ " chip board

2) Wrapping the door skin around the wood circles

3) Marking were to cut the arm holes

4) Making the patterns for the arm hole backing plate

5) Making Paper patterns for the arm recesses

6) Resin covered mat board arm hole recesses

7) Fiber glass arm backing plates

8) Forming the dome from 2" urethane foam insulation

9) Final diminsioning of dome while spinning

10) First coat of fiberglass

11) Jig for accurate dimensioning of dome

Close up of jig, router, and 1/4" 4 flute ball end mill. This gives your torso that "just machined" look ;-)

1) The rings were centered using 2 pieces of wood in an "X" configuration.  

2) The door skin was wetted overnight, and pre-formed in a cylinder prior to application to the wood rings.  

4) Patterns for arm back's were re-done prior to use - See #5.  

5) Patterns were transferred to ½" plywood that was wood screwed to a square piece wood screwed between top and bottom rings. This allowed accurate positioning in 3 axes planes - X,Y,Z. Of the arm bases. The paper pattern for the arm recesses, was transferred to mat board that was hot glued to the inside of the torso, and to the circumference of the plywood backing plate. This accurately formed the circular arm hole end plate. 

6) Fiber glass resin over mat board 

7) Fiber glassed end plate allowed removal of wood backing plate. The inside arm recesses were also fiber glassed over to add strength, and secure them to the torso. 

8) Foam stack about to be shaped. 

11) View of shaping jig and turn table used to rotate torso while each circular cut was made in dome.