Both the dome and slab design use a 5 gallon bucket in the middle to be used as a squat hole

FINAL MOLD DESIGN

Two metal strip semicircles connected by flanges, that are welded on, and uses bolts to connect the two halves.

Notches for handles on both sides

Plastic sheet laid underneath mold for finishing purposing

Easily Reusable/ 2’’ thick

Build per drawing

“2-D” CIRCULAR SLAB MOLD

DOME MOLD

• Plastic Sheet used a barrier to protect the mold

• Reusable • Made from Styrofoam and

wood• Inverted so better finish shows• Build instructions on following

slides

Cut 4 sheets of 1 ’ ’ th ick hous ing insulat ion foam to 30’ ’x30’ ’

Using a two part epoxy, g lue the 4 ply’s on top of each other only glu ing in the area in the corners as shown in b lack to the r ight . C lean surface complete ly before glu ing.

Apply pressure us ing c lamps or sett ing weights on top and let cure overnight (24 hrs) .

On the top ply measure out a 30’ ’ c i rc le , then measure out a 25’ ’ c i rc le that is concentr ic to the 30’ ’ . Cut out the 25’ ’ c i rc le going down only 1 ’ ’ through the top ply and remove al l mater ia l f rom top ply ins ide the 25’ ’c i rc le .

On the next p ly measure a 20’ ’ c i rc le concentr ic to the 30’ ’ c i rc le . Cut out the 20’ ’ c i rc le going down only 1 ’ ’ through the second ply and remove al l mater ia l f rom second ply ins ide the 20’ ’c i rc le .

-On the next p ly measure a 15’ ’ c i rc le concentr ic to the 30’ ’ c i rc le . Cut out the 15’ ’ c i rc le going down only 1 ’ ’ through the th i rd ply and remove a l l mater ia l f rom thi rd p ly ins ide the 15’ ’c i rc le .

DOME MOLD ASSEMBLY

Tools Needed-Flat stiff pieces to spread epoxy/bondo (ex old credit card)-Sand paper (belt sander will help go faster)-Screwgun for wooden box-Car Bondo for mistakes

Take a fi ve ga l lon bucket and t race out the bottom of the bucket for the bottom p ly that i s concentr ic to the 30’ ’ c i rc le . Remove a l l the mater ia l ins ide the c i rc le on the bottom p ly.

Sand down the mold in to the des i red dome shape.

Can ver i fy dome curvature by making a ha l f c i rc le wi th rad ius 30.125’ ’out o f cardboard or p lywood, ver i fy w i th the webs i te be low.

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Move the ha l f c i rc le around perpendicu lar to the dome unt i l the arc o f your 30.125’ ’ ha l f c i rc le i s fl ush, s imi la r to how a mi l l d r i l l s out a ho le in a p iece o f meta l .

I f the ha l f c i rc le i s not fl ush a l l a round cont inue the sand and bondo techn ique.

Use Bondo to fi x any imper fect ions and sand aga in . Repeat unt i l complete .

Use s t r ips o f duct tape to cover the mold once complete

Bui ld a wooden box around the Styro foam to protect i t f rom damage and he lp make t ransportab le .

DOME ASSEMBLY CONTINUED