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assembly

Making the Wood Deck
Above you can see the completed wood deck. Here are instructions for how to make it.

One of the key concepts for the deck is that the verticies at the top of each riser are not covered by wood. They are exposed so you will be able to attach an angle bracket to it to hold the 1v shade dome on top.

The instructions below assume you have a 2v optimal dome. If your dome is bigger or smaller, you'll have to improvise.

  1. Place one of the two sheets of 5/8" plywood on top of the deck.
  2. Slide it into position so that all the following are true: When all the above conditions are met, that sheet of plywood is in the right spot.
  3. Clamp that sheet down so it won't slide (or else be very careful not to move it when you do the following steps.
  4. Place the other sheet of plywood onto the deck.
  5. Adjust its position so that one long edge exactly aligns with the long edge of the other sheet you just placed. Of course, the center bolt will be sticking up and will keep you from laying it flat. You could lower that bolt, or you could just live with the fact that it doesn't lay flat for the moment. Do your best to align the long edges, so that if there was a hole for the bolt to go through, the two sheets would exactly meet.
  6. Climb down. Bring a step stool into the dome and stand on it so you can trace the outline of the dome deck onto the bottom of the two sheets of plywood.
  7. Mark where the center bolt goes. I put a 1" circle centered on the bolt.
  8. Mark where the two verticies are on the sheet that covers the center bolt. Mark those verticies so you can cut some plywood away from them to expose the verticies.
  9. I cut the plywood with a jigsaw while it was sitting on the dome deck by staying aware of where the struts were, and moving the plywood so that the jigsaw blade never contacted any struts. I also had to remain aware of where the struts were so that I didn't lose my ballance or step on an unsupported part of the deck. If you're not comfortable working in such a precarious position, bring the plywood sheets down and cut them on sawhorses or by placing scrap wood under them so there is clearance for the jigsaw blade.
  10. Use a drill to make a hole for the center bolt.
  11. Use the jigsaw to cut the space for the two verticies in the sheet with the center hole.
  12. Place the plywood deck sheets back into position and verify that the five verticies at the top of the risers are exposed. Attach an angle bracket at the top of each of these verticies, to be sure they will fit and to be ready for building the 1v shade dome.
  13. Optional: cut handholds around the permiter of the dome deck, and use a router on the edges to make them smooth. Click here for step-by-step instructions.

All information herein copyright 2007 by Howard Cohen
hoco@timefold.com