multiple sketches were drawn on iPad
multiple brainstorming sessions with mentors,
to use recycled plastic to make slats for the seating
to use wood as the frame of the bench
how the hydroponics would wrap around the bench
how the hydroponics would be constructed with or around the bench
the bench dimensions
the size of the SHIFT space
order UV lights, pump, timer, tubes, bucket, reservoir with Ben
UV lights on arms must be ordered on Amazon (only 1ft) - Ben has smallest 2ft long UV lights
PVC pipes are perfect
wood materials for the frame of the bench
recycled plastic for the seating (plastic slats) - polystyrene
flat-head nails & screws (try both with plastic) and wood glue for assembly
PVC pipes, reservoir, pump and UV lights for hydroponics
2x4" wood pieces - cut at Home Depot
1x4" wood pieces - cut at Home Depot
6d 2" wood nails
produced a polystyrene plastic sheet with the sheet press
cut 26cm x 26cm plastic sheets in half
melted the 13cm plastic sheet using the "?" machine to fold it in a "U" shape
molded the plastic sheet on a piece of wood using clamps to keep it in place
met with friend for help to use Inventor/Fusion
import parts from McMaster-Carr website
3D designed all pieces for the bench, referring to the final sketch for dimensions
Met Felix at CVM workspace to produce plastic sheets for stress testing.
tried 250g of polysterene in 1/8 inch sheet press, too many holes
300g polystyrene for 1/8 inch sheet press fills perfectly
600g polystyrene for 1/4 inch sheet press
molded both size sheets into "U" shapes for stress testing
reached out to lab technician to test the plastic sheets at Concordia University
placed the sheet on wood pieces and inside the compression testing machine and recorded the compression data
repeated the procedure for each plastic sheet
1/4 in plastic sheet yielded a compression strength (before failure) of about 347kN
1/8in plastic sheet yielded a compression strength (before failure) of about 183kN
edited length of plastic slats
added wood spacers to the plastic slats for more strength
added holes into plastic slats for metal rods
changed height and width of wood structure
weighed 300g of black & white polystyrene plastic using a scale
sanitized metal sheets for the sheet press
used 12in length/width square & 0.125in thickness frame for sheet size
poured polystyrene within the boundaries of the frame
snipped red colored polysterene bits over the 300g of plastic
placed colorful polystyrene bread bag clips over top of the 300g of plastic for added color
placed another metal sheet on top and placed it in the sheet press
after the melting is completed remove from the sheet press and let cool with heavy metal sheets placed on top (prevents plastic from warping as it dries)
remove dried polystyrene sheet from metal frame and use a metal blade to smooth the edges
measure and mark half of the plastic sheet
cut the polystyrene sheets in half using a large slicer
adjust metal rods on machine to thickness of bench slats needed, about 3cm
adjust ruler pointer on machine (about 80cm) on both ends
turn on machine and let the metal string heat up (about 15 minutes)
place plastic sheet aligned with ruler and on top of metal strings
close the upper metal strings over the plastic sheet
let the plastic heat for 2min20sec
remove the sheet with heat resistant gloves
quickly place heated plastic sheet over wood piece (about 3cm in width)
use clamps to secure the sheet and make sure it dries in a hollow rectangular shape ("U")
turn on a fan nearby to speed up the drying process (about 15sec to dry)
using 2x4" wood pieces, cut in 1/2 using a vertical saw??
cut the above pieces to 3in in length
smooth the sides of the 3in pieces with a planar saw
insert two 3in pieces at the ends of the plastic slats
repeat this process until you have about 64 3in wood pieces
with wood glue, attach two pieces of 2x4 wood to a wood sheet, creating a 90degree angle and let fully dry
place the plastic slat from STEP 16 into the 90degree angle
align the 3/8in diameter drill with the end of the plastic slat, the hole will be created through both sides of the plastic "U" and the 3in wood piece
repeat this for both ends of the plastic slat
repeat this process for all plastic slats (about 32)
using 1x4" wood pieces, cut into 5in (in length) pieces using a saw
repeat this for each 1x4" wood piece, you will have about 24 pieces total
Buy:
5x 1x4" wood, 8ft in length
5x 2x4" wood, 8ft in length
2x 2x6" wood, 8ft in length
3x metal rods 3/8in in diameter
20x 3/8-16 size cap nuts
20x 3/8 size washers
4x small L-brackets
1x box of wood screws of 8x1 1/2 size
1x box of wood screws of 8x3 size