My son needed a building with at least 5 rooms that he could wire with a group for a project at school. The have to put lights and other electrical devices into the home. He went to work in sketchup and designed this castle.

It's amazing how you can't tell how big something really going to be until you start cutting. This going to be bigger than the kitchen table.

Made entirely from 1 inch Dow Blue foam. I think we used about 4 full 2' x 8' sheets. Everything is tab and notch with keystone corners. Doesn't require any glue. We ended up at about a 85 inch per minute feed with a 1/8 x 1 1/8 3 flute end mill cutting in one pass. The only problem we had was when we were feeding too slow, below 70 in per minute, that it would melt foam to the bit and make a mess. Increasing the feed rate and keeping the router on the lowest speed (20,000 rpm) seemed to work great)


Here is the Keep in a 3d view. I'll post some pics tonight after he gets it all assembled. This 3d view is just a small part of the castle. This thing is strong enough for kids to play with. The tabs on the bottom are for the entire castle to assemble into a base board.


SlowBipe Attached files Castle.skp (1 MB)Â

 

Here is a picture of my son working on his project.




Now here are some pictures of the castle all assembled. My son is taking it to school tomorrow where they will wire it like a home but using low voltage and then paint it. I'll try to get some more pictures once it is completed. Total Size is about 52" long by 25" deep and 26" tall.

SlowBipe


Attached files

 

Looks great!! I can't wait to see it all painted and wired up!

Tim
AG4RZ

 

That is Awesome, Great Job guys!!!! :fantastic:


John

 

Nice castle.

Now all you need is some sliders and you got it made. :ROFL: ( just kidding.)

Put some small LCD displays behind the windows with video of folks walking around inside the castle.
I did that for a building display once, and it went over very well.

Nice job. I like seeing stuff like this.

Cheers.
George