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  #61  
Old 06-07-2024, 08:56 PM
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Originally Posted by Leo.G View Post
That's looking amazing Anthony!
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  #62  
Old 06-07-2024, 09:19 PM
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Sliding Shutter

Today's job was putting together the rollers for the shutter. I had previously cut out and assembled two plywood arc that matched the radii of the dome opening. I then drilled an attached ten 20mm rollers to each one, then attached them to the shutter frame using aluminium flat bar; this is only a temporary, have a nicer solution which I will implement in the coming days

Put the whole unit on the dome and with great relief the shutter rolled smoothly along the tracks without an issue. Very happy with the result so far.

Cheers
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Last edited by anthony2302749; 07-07-2024 at 07:07 PM.
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  #63  
Old 10-07-2024, 12:05 PM
Leo.G (Leo)
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That's a very impressive build Anthony!
Here's a weird question, did you waste a lot of ply doing the large radius bends?
It's stopped me doing certain builds in the past, knowing I'd only get a few large radius bends out of each sheet and marine grade ply being somewhat expensive.
I have resorted to doing stacks of thin strips bent and glued for smaller jobs, nothing like a dome though. That I haven't tried building and wouldn't have a suitable place (or room, or area unobstructed by neighbours trees) in the back yard to put one.
One day I'll win lotto and buy a property where I can have a dome. I'll probably drop dead before that happens.
Though if I were to win I'd probably be too busy playing with expensive Italian motorbikes.........
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  #64  
Old 10-07-2024, 05:49 PM
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Quote:
Originally Posted by Leo.G View Post
That's a very impressive build Anthony!
Here's a weird question, did you waste a lot of ply doing the large radius bends?
It's stopped me doing certain builds in the past, knowing I'd only get a few large radius bends out of each sheet and marine grade ply being somewhat expensive.
I have resorted to doing stacks of thin strips bent and glued for smaller jobs, nothing like a dome though. That I haven't tried building and wouldn't have a suitable place (or room, or area unobstructed by neighbours trees) in the back yard to put one.
One day I'll win lotto and buy a property where I can have a dome. I'll probably drop dead before that happens.
Though if I were to win I'd probably be too busy playing with expensive Italian motorbikes.........
Hi Leo

There is minimal loss of plywood when cutting the radius bends. I used a 6.4mm router tip for the cutting as recommended, so possible loss 12.8mm in saw dust. After the initial cut, the scrap plywood between each radius would be about 15mm at its thickest. On a good setup you could utilise say 80% to 90% (ballpark figure) of the plywood as usable timber.

Cheers
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  #65  
Old 10-07-2024, 06:10 PM
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Rejigged the shutter and installed the tracks.

Past couple of days I have rework the Shutter and the track that the shutter rolls along. The shutter I replaced the aluminium for plywood block to affix the roller to the shutter frame, a workable solution, probably still need to tweak it a bit.

As for the tracks I ditched the colour bond strip for aluminium 25mm flat bar. After returning two pieces of 25mm by 3m aluminium flat bar to Bunnings for a refund of $28. I then when to Action Aluminium and picked up four pieces of 25mm by 4m aluminium flat bar for $30. Note, don't skimp.

Method used to create the tracks was to layer up the aluminium and yellow tongue and gluing them into place with Gorilla Glue ensuring everything was square and aligned correctly. Once dry screwed into place.

End result is the shutter now roll smoothly over the dome.

Cheers
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  #66  
Old 11-07-2024, 12:09 PM
Leo.G (Leo)
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You'd have to be extremely happy with your results Anthony, the dome looks amazing and it's easy to see how much work you've put into it.

Bunnings are thieves when it comes to steel and aluminium. I can buy 6 metre lengths (or 6.5M) from a steel supplier in Bathurst for less than a 1 metre length of the same thing from Bunnings, same with steel.
Bugger, I drove straight past the other day taking my son to an ENT in Orange and never thought to grab some stuff I needed. I have to take my son to Bathurst for an MRI next Monday, I better write a list.
I don't like driving (it's a migraine thing) and while Bathurst is only 45 minutes away I seldom go there.
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  #67  
Old 13-07-2024, 04:22 PM
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Bottom Shutter

Been a couple of busied days on the observatory build. This post is about the construction of the bottom shutter. Fairly straight forward job.
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  #68  
Old 13-07-2024, 04:41 PM
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Main Shutter is nearly complete.

I have made some more improvement to the Main Shutter, one being the roller bearings. I was not happy with them affixed to the timber, so I remounted them on right angle aluminium and then attached them to the shutter frame. If I need to replace one, it just makes the job easier. Also need to fix the spacing between the out-roller frame and the inner frame due to the remounting of the rollers.

Final task was to cover the Shutter frame with 3mm plywood. This was done with the Shutter frame in place and glued, covered with ply, stapled into position. Only task left is the cleaning up overhanging plywood, fill in the holes, sand and fiberglass the edges for waterproofing.

How well does it work, very well, Happy with the results.

So, the dome as a whole is almost complete.

Cheers
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Last edited by anthony2302749; 13-07-2024 at 05:21 PM.
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