Thread: Prototype + triangles = headache :(

At 10cm by 3cm, I'd make it from solid timber, using a band saw and disk sander
But first I'd use your CAD program to print a set of templates to aid with sizing each face

A bandsaw and disk sander is a serious investment if you only plan on making one or two

I'm thinking something along the lines of a disk grinder/sander that jewelers use to shape gems.

How about nice sharp chisels/block plane. Glue the uncut timber to a smaller base that can be held in a vise / carvers vice then away you go

My knee-jerk response = I'd begin with the templates, a bread knife and a block of styrofoam (or cheese if you got the munchies). Make one. See what the puzzles are.
At the very least, the stock material won't fight back.

Just make a cube instead

I've been thinking about it more.. and all it really is is a pentagon with the sides shaved off.. I think the template idea is the way to go, I'll draw a triangle on the top and then use that as a guide. As I've got it in cad i can work out precisely what the angles are to make some mounting blocks.. I'm thinking I need to find a disk sander.

Does anyone know if there are any public access woodworking workshops in the melbourne area?

You need a set of patterns, the block of cheese, a box of dry bikkies, a knife and a flagon of dry white. With those tools, the organization of the project will take shape.

Wet snow/lumpy rain, S wind at 50kph, gusting to 80. I would really like to come and help.

Like this, you mean?
I reckon it would be just about impossible to make from the solid.
The easiest way is to first cut your triangles a bit oversize. Then cut a triangle out of a piece of ply or MDF thicker than your triangles, that your triangles will fit into. Also, make up a stick with a rubber/plastic button on it, to hold your triangles in place. Set the tablesaw at the correct angle (you'll have to look it up, I can't remember it off the top of my head). Then trim each edge of the triangles to the correct angle. Tape what sides you can together flat with masking tape, and try them to make sure they fit. Then
lay it down flat, inside up, and glue like mad. As you fold the sides together, tape them together. If you want to make a box that you can open, wax and don't put glue on those edges.
Good luck!

Wow! AlexS - amazing work - still can't believe someone on this forum has already attempted an icosahedron box - i must be in the right place.

thanks for the description too, I've got a drop saw at my disposal which might just do the trick... though admittedly i've only ever used it to build a deck.. but angles are angles i figure

Alex, any chance you have the second photo of your icosahedron opened? it's not showing up in your post when i click on it.

Hope this helps.
You should be able to make it using a drop saw as long as it's set up accurately. It's essential that the triangles are exactly equilateral and the same size - you probably need to make a jig for this.
If you google Platonic Solids you will find maths sites that give you the bevel angles .... unless you want to work them out yourself (Hint: Napiers rules)

Good luck, look forward to seeing pics.

Thanks for the heads up on the bevels AlexS.

Question, are they magnets holding it together? And if so do you know where I can find a supplier for them as i planned to use a couple in my design.

cheers.

Yes, they are 3mm neodymium magnets from Maglab. Reasonable price and good service.

When you set your bevel angles on table saw, bandsaw, CMS, etc., use a CAD-generated template, NOT the gauge on the tool. Ditto for protractors.

Cheers,
Joe