Day 6: Learning through making

Starting early in the morning we split in 2 groups, one started to make the lap joint that we had been working on during the weekend and the other group stayed in the Archive room to fill Alex in on our progress so far. Through the meeting we came to the realization that the frame we had already designed was a bit flimsy but had the potential to become stronger and sturdier as a laminate piece. Instead of using the timber posts already in our disposal we came up with the idea of laminating plywood panels together to create a better base and junction in terms of flexibility and load bearing.

Getting measurements for the cutting lines on the timber panels (Group 1)

Initial idea of junction between posts and beam

Morning meeting with Alex (Group 2)

Confronting our problems through sketchin

We grouped up as a single unit to discuss this idea and came up with sketches and different scenarios about  how we  could   use  the  plywood  panels  to create our  whole  design concept. First  idea  based on this theory was to  have  4 plywood  panels as  a base and beam  ( 2 on each side ) and in the middle there would be  an ''L''  shaped   plywood   laminate that  would  act  as  a  brace  between  the 2  sides. Apart from that bracing there would also be smaller pieces alongside the length of the beam and the post to hold it together.

We talked this idea over again with Alex and decided to go for a prototype that would be a small variation of the one we thought of. This version consists  of  3 pieces of plywood not put  together but  braced with  each other with timber in between creating a three layered sandwich that would  make the frame even  stronger. In my  personal  opinion  we  weren't  quite convinced  it would work out  but through constantly  improving the design while cutting the pieces, it turned out to be a really successful design process.

Presenting our model of the plywood panel idea

Cutting the plywood panel in identical pieces

Measuring and  drawing  precise  lines 

is essential to this part of the project as we are trying to create a prototype of the base and middle part of the post to get a sense of what is working and what is not.

Cutting the strips of plywood in 3 identical pieces

Experimenting with the possible variations of junction

Experimenting with different types of wood for bracing

Ply-timber-ply-timber-ply
The composition of our module

On the middle piece (picture below)
we create some kind of socket so it
can interlock with other pieces
vertically.

Cutting holes on the small bracing pieces for the pegs to go through

Inner brace for the base module

It seems  like  we cant  create a  lap
joint using plywood since the pieces
that the ply  consists of break  apart
when cut. Instead, we created a peg system which locks all the pieces together.

Composition of the base module

Our first prototype is ready

Workshop 7 after a long and hard Monday

 For the base we came up with a peg system that increases the total length of each post which is useful in the case of slanted ground. Through the creation of this part, we came across another problem that still needs to be addressed which is the base unit. A solid base is still required for the post to fit in and lock in place for more stability.

 If there is one thing to take away from today is that through the actual making of the prototype we spotted numerous new problems and found solution for previous ones that puzzled us. Coming up on Tuesday the construction of the 1:1 module which seems like a relatively easy thing to do, now that we are equipped with all the new experiences from today. An early morning meeting is scheduled for tomorrow at 10.00 am to work out the issues that still trouble us and get our hands on the 1:1 module.