Build Day

Loading the van

Today was the day. After two long weeks of planning and fabricating, we we're finally going to site to build Tube Cubed.
The morning was the earliest start we had had. At studio for 7:15am, the day began by finishing off putting the inserts into the tubes and PVA-ing the insides of the tubes as well as touching up on some of the varnish. We then set about dismantling it and cleaning up. The tubes were once again arranged in their rows to make it easier to construct once we reached Dunham Massey. The van arrived soon after 8:00am so we loaded up and were soon on our way, travelling in convoy of three cars, a van and a group of people on the buses.

It might be a bit on the small side . . .

Once we reached Dunham Massey, we were slightly more awake and as I was travelling with Siobhan and Fran, I arrived before the van so we headed over to site with the model. The van came soon enough so we set about unloading every thing and after three trips in the quad-bike-trailer-vehicle, everything was onsite ready to be built.

First thing first was getting the bases level and in the right place. This involved using the spirit level and one of the frame pieces while we shifted them around and put rubber squares underneath them to stop it from sitting in standing water when it inevitably tipped it down.

The team looking somewhat confused

While this was going on, we had a team bolting the frames together ready to be put in as soon as we were happy with where the pavilion was going to stand. 

The official way of testing structural stability

The frames went in quickly and to secure them, we wedged pieces of rubber between the frame and the base. Before we went any further, we had to make sure it was structurally sound. This involved team members hanging and swinging off it and generally making like monkeys!

Needless to say, it passed.

After that it was Tube Time. As we had practised, we started with row A and were working our way up but some of the tubes had got mixed up in transit so it turned into a bit of a free for all. I escaped around the back to make sure that they were all level with each other and the bases.

It's Tube Time!

I see you!

It didn't take long to get them all in, although we still had a couple of problem holes to sort out. These took the longest to do and to make a long story shorter, we took turns to try and get the holes in the frame wide enough to get the tubes into for most of the day. Our techniques included filing, sanding, chiselling and even drilling and none of them seemed to be having much effect whatsoever. 

Whilst this was happening, or rather, not happening, we were having problems around the back. It looked messy and we were told that it may even pose a health and safety risk due to the nails that hadn't been put in properly. We needed to sort it and sort it is what we did. 

First things first and that was to get the pins nailed in all the way. This called for some serious quality control and any nails that hadn't gone in straight or couldn't go in any further but needed to were pulled out and put in again.

Once this was done, we then got onto tidying up their appearance by sanding down the surface and applying a new coat of varnish.

We secured the tubes in place by placing pieces of rubber between the tubes and the framework. This was to stop them moving or being taken out. 

The frames were still being filed and sanded when we began discussing how we were going to brace it because, despite wedging rubber into the nooks and crannies, it still had a bit of a wobble going on. It was talked about on the previous night and metal rods were considered although we didn't have much of an idea of how to attach them.
A group was sent to B&Q with strict instructions of what to get. They returned with metal rods, nuts and other bits and pieces that were needed, including some new files which were received with open arms to those who were still filing holes. These new files got the job done and there was plenty of celebrating when the last of the tubes went in. 
The guys who were working on the bracing got one rod in before we had to leave and the difference it made was noticeable straight away.

Soon it was time for team photos and to go home due to lack of light but the plan is to come back on Tuesday to finish off the bracing and securing the tubes in place.

The finished article

Some of the original design team

There was obviously something more interesting than
the camera!

The Day Before The Build

Guys . . . I don't think this is right . . .

T minus 24 hours and in that time we had to have our dress rehearsal and smooth out any rough edges (quite literally)
The morning started with with bolting the frames together and sorting the tubes ready for insertion. After the back frame was complete, we tested the tubes and I don't know about the rest of the group but I was pleasantly surprised to see that there weren't too many that didn't fit. We made a note of the ones not playing fair with the intention of sorting them out later.
The original plan was to get it up before lunch but as with even the best laid plans, it was not to be. So after a quick lunch break, we split into the teams for the build. The stop watch was started and it was all systems are GO!
First up was the bases. These were lined up by using one of the frames and once we were happy, they added the other two. The cross bracing between frames came next and then it was time for the human conveyor belt to make another appearance. 

And then it was up! Just like that.

Nearly there!

This. Tube. Will. Fit.

Once we had finished admiring our handy work, we began to sort out the problem holes and work on putting the inserts into the ends of the tubes. This was simply a case of finding an insert that fitted into a tube and nailing a couple of pins to hold it in place.

That afternoon we were on such a high from actually building it, not very much seemed to get done. However there was the issue of the pavilion having a wobble. A big wobble. This is currently under scrutiny and a plan is being thought up to sort it out. Something along the lines of tensioning cable or metal rods diagonally down the sides of the pavilion.

Never give an angry Welshman
a sledgehammer

Big frame, little frame, cardboard
tube

Death by tube

Black Friday

Just for the record: Not a lot happened on Thursday. It was, of course, lectures but a very small handful of us volunteered to come to the Shed super early and chop down the forest (continuing with the metaphor from my last entry). This involved us meeting at 8.30am with the plan to be finished in time to get to lectures at 10am. We managed it and the tubes were stacked on shelves in alphabetical order by the time we left ready to be worked on that evening after lectures had finished . . . . . 

That didn't happen.

Third year were using the room and we would have to wait at least an hour before we could get in there, by which time there would hardly be any point in us starting varnishing. So we all got a well needed early night.

Onto Friday!

Nothing seemed to be going right on Friday. Despite planning on a really early start, it was a slow one as we were moved from place to place due to the spaces being used for teaching. 

Once we had finally settled, SamSam were off to the workshop to CNC the frame. The pieced that had been CNC-ed were then bought back for us to chisel out the circles (which seem to be taking over EVERYWHERE now!) and sand the frames down ready for coating. Sheel and Taniya were sent, once again, to B&Q to pick up said wood varnish.

Progress was also made on the inserts and over lunch, I heading over to the workshop with some 120 off-cuts to get them sanded for the craft fair. 

Whilst all this was going on, it had begun to rain so we had to quickly get all the still-slightly-wet tubes in before sending Sheel and Taniya to swap the wood varnish because it wasn't actually waterproof (???) 

Filing and sanding on the frames continued for the duration of the day but Clara (who would be coming with me to the craft fair) and I managed to escape and decorate some of the beautifully sanded off-cuts. 

By the time Sheel and Taniya got back to the Shed, it was closing time. However, Siobhan had managed to get the Shed open over the weekend for us to continue, but Shhhhh, it's a secret!

Of Road Trips and E-mails

Friday saw the group spending all day in the library. The big event of the day was probably getting the sponsorship pack sent off to about 260 local architects. 
The brochure was nearly ready Friday morning but we made some tweaks to it - aligning the text etc. The brochure was finally ready after lunch so we tried to send it. They bounced. All 260 e-mails. This called for drastic action so three of us took it in turns to send e-mails individually from the account. That didn't work either. In the end, Jamie was able to send the e-mails via his university account, with minimum bounce back. We are now awaiting replies . . .

Trying - and failing - to send the e-mails

Tomorrow, some of the group are going on a road trip to pick up our tubes. We are hoping that they will be back by around 3pm so we can make a start on the waterproofing. Two of the group were going to look at different coatings over the weekend and have a go at testing them. They were researching on Friday. 

With regards to the framework, we had an e-mail confirming that the costs of the workshop would be covered by the school so that is one less cost to worry about.

There have been a couple of minor changes to the structure. This is just to make it more sturdy and involve using off-cuts to create cross-bracing within the pavilion. This is being looked into by Joe with Oli's team also helping to source the plywood and the materials needed to put it all together. They also worked out how many CNC hours we will need to cut out the frame: about 2 hours a sheet and we have 13 sheets. Not only that but it will be a fight to the death to get to it as there are 4 other groups who also need to use it. 

We are meeting at the library again today so I will update you on all the goings on later!