Author Topic: Building the pyramid frame without welding (Read 26895 times)

skywatcher · « **on:** December 14, 2007, 08:27:07 PM »

For various reasons, i decided to build the pyramid frame without welding.
One of the reasons is increased flexibility (for making experiments or to simplify transport).

First we make the base, which is quite easy because there are only nice 90 deg and 45 deg angles.

Step 1:

Mark a 45 deg angle on the ends of the steel pipes and cut them:

skywatcher · « **Reply #1 on:** December 14, 2007, 08:29:12 PM »

Step 2:

Drill some 4 mm holes into the tubes to mount flat steel angles (they are 120 x 120 x 20 mm):

skywatcher · « **Reply #2 on:** December 14, 2007, 08:30:53 PM »

Now it looks like this:

skywatcher · « **Reply #3 on:** December 14, 2007, 08:31:39 PM »

The finished pyramid base:

skywatcher · « **Reply #4 on:** December 14, 2007, 08:33:56 PM »

Now we will prepare the side tubes.

Step 3:

Mark 54 deg angles as shown in the picture. This gives the lower ends of the tubes. Cut the tubes at the marked lines.

skywatcher · « **Reply #5 on:** December 14, 2007, 08:36:17 PM »

Step 4:

Mark 39 deg angles at the other ends of the tubes. This will give the upper ends.

skywatcher · « **Reply #6 on:** December 14, 2007, 08:37:17 PM »

After cutting, it should look like this:

islandan · « **Reply #7 on:** December 14, 2007, 08:37:29 PM »

splendour

skywatcher · « **Reply #8 on:** December 14, 2007, 08:40:36 PM »

Step 5:

Make slots at the lower ends of the tubes, parallel to the cutted edges, approx. 3 mm from the cutted edges, and 3 mm wide.
The width depends on the steel plate you will put into this slot (described in the next step).

For cutting the slots you could use a wire saw with tungsten particles (is used for cutting tiles).

skywatcher · « **Reply #9 on:** December 14, 2007, 08:45:11 PM »

Step 6:

Put a piece of steel into the slot, as close to the outer edge of the tube as possible.
(it's better to drill the hole after this)

Mark the steel at the outside of the tube (on the side which is closer to the edge of the steel tube) and cut it on the marked lines.
Then put it into the slot again, and make the marking for the 4 mm hole which should be 15 mm from the tip of the tube (see picture):

skywatcher · « **Reply #10 on:** December 14, 2007, 08:48:02 PM »

Step 7:

Make a M5 thread into the 4 mm hole, so that a M5 screw (M5 x 32 (use M5 x 40 and cut it to 32 mm)) fits into it:

skywatcher · « **Reply #11 on:** December 14, 2007, 08:49:31 PM »

Side view (the screw should have a right angle to the cutted edges oft he tube, and be 15 mm away from the outer vertical edge):

skywatcher · « **Reply #12 on:** December 14, 2007, 08:52:29 PM »

Step 8:

Drill a 5 mm hole into the base frame at the diagonal, and 15 mm from the corner (measured on the diagonal).
If you use the same flat angles as i used, you can use the 4 mm hole which is already in the angle to center the drill.

Now you can mount the side tube to the base with the M5 x 32 screw:

skywatcher · « **Reply #13 on:** December 14, 2007, 08:55:15 PM »

The connection is of course not as stable as a welded connection, but it is sufficient to easily support the weight of the side tube.
When all tubes are mounted, the stability will be more than sufficient.

Tomorrow i will make the connections at the top of the pyramid, this will be more easy than the connections to the base.

titof · « **Reply #14 on:** December 14, 2007, 09:26:06 PM »

excellent idea...

but how to do with the top ?...

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Author Topic: Building the pyramid frame without welding (Read 26895 times)

skywatcher

Building the pyramid frame without welding

skywatcher

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skywatcher

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skywatcher

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skywatcher

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skywatcher

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skywatcher

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islandan

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skywatcher

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skywatcher

Re: Building the pyramid frame without welding

skywatcher

Re: Building the pyramid frame without welding

skywatcher

Re: Building the pyramid frame without welding

skywatcher

Re: Building the pyramid frame without welding

skywatcher

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titof

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