I bought Tony Wright’s GF last fall but didn’t have a chance to use it due to a bit of spousal paranoia (plus I could just use the one at work), so I’m happy to report that it survived the move to Austin and is running great. No smoke in the house at all, wife is happy.
I finally got a chance to try something I’ve been thinking about for a while. Previously I’d made an icosahedron and a dodecahedron (20- and 12-sided polyhedra), and I was curious how they’d work as spheres by rounding the edges. Then it hit me that since they’re duals of each other (one has its vertices where the other’s faces are and vice-versa), the edges are perpendicular. That means we can make a composite of both shapes, with the edges notched and slotted together. After a whole lot of futzing around trying to remember how to Inkscape then only about ten minutes cutting but then a lot of figuring out how to put it together, here it is!
It’s a deltoidal hexecontahedron, says Wikipedia, 60 kite-shaped faces. It uses 30 each of the short and long edge pieces, 20 triangle connectors, and 12 of the pentagonal connectors. I used Woodpeckers 3 mm Baltic Birch, so the slots are tuned to that, 2.9 mm at the mouth and 2.85 mm at the back. I did my previous shapes in Proofgrade Maple and 3.0 mm slots gave a good fit.
Here are the component shapes built separately:
I originally tried to put this together by building the icosahedron first then the dodecahedron on top of it and snugging it together but I couldn’t get the edge pieces flush with each other. I need some kind of L-shaped thing I could poke through to pull from the other side…? Can’t think of what I could use for that. So instead I paired up the long and short edge pieces first then built up the shape as loosely as possible and snugged it all together once everything was in place, a bit at a time all the way around. If you tighten it up as you build it’s impossible to get the last pieces in.