It is now January, 2008 & I am starting to document how I designed & built a copper pyramid back in 2003. For this project I chose to use 3/4" copper pipe. Using my method, you will need the following equipment.
1. A hack saw or similar to cut the pipe. (easy part)
2. A dremel to cut some excess metal away on the bottom corner pieces.
3 . A propane torch to sweat the pipes together. (tough part)
4 . Create a make shift miter box to cut the odd angles.
5 . Create a jig to hold 3 corner pipes in place while you solde.
(I made mine out of wood & it barely made it through all of the soldering process. See last photo for reference)
I finished this project back in June of 2003 with ideas from others & a next door neighbor that sweated the pipe for me. The top piece & 4 corners I made 6" long with unions to facilitate making the pyramid any size I wanted. I drew the pipes in 3D in AutoCAD to see how they fit together. The top piece turned out to be 2 simple angle cuts with the hack saw. The bottom pieces were also 2 simple cuts, but also had to cut away some of the pipe with a dremel tool. I originally was not going to create the bottom corner pieces, but just use copper tees & 45's. A friend told me this would not work for my intended purpose, so I created the corners also. Here is a series of photos showing how the top piece was constructed.
Top Piece in PDF format This shows 4 views of the top copper piece. To cut the pipe to this shape, cut out the bottom right paper template & wrap it around about a 7" or so piece of copper pipe. This will give you the guide to cut each of the 4 pieces that make up the top section.
Bottom Corners in PDF format This shows the bottom corner copper pieces. The pieces that meet at 45 degrees are of course a simple 45 degree cut. The template for the piece that goes up at an angle to the top is shown in the top right view in the pdf file.
Spreadsheet to calculate the base and side lengths of a pyramid. You enter the base total length & angle of pyramid & the spreadsheet will calculate the angled pipe length & the actual base length. I use a 52 degree angle for the pyramid. For the Actual base length I substract 6" for each corner, which comes out to 1' since each pipe is connected to 2 corners. The spreadsheet has numbers filled in from 1' to 10' base lengths in increments of 6".