This is a 15' diameter, 2 frequency dome. The dome was made from 1 1/4" EMT. The struts were cut to the 2 required lengths from standard 10' conduit using a metal cutting chop saw with an abrasive blade. The shorter struts were dipped in red paint; the longer ones in green. The ends of the pipes were flattened using a 12 ton shop press.
The pictures below show the shop press in action. After flattening one end, the flat end was clamped to a work surface while the other end was flattened. The ends were then bent to the appropriate angles (again using the press) and then drilled with 3/8" holes using the drill press. Finally, the 65 pipes were assembled in a dry run before finishing the struts.
The two sets of struts were dipped in metal paint and color-coded by length. Finally, the dome could be setup for the first time with finished struts. It is a very sturdy structure.
