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Building a large sphere, how to frame?

18812 Views 15 Replies 11 Participants Last post by  Mellony
Hey everyone, I'm trying to devise a way to build, well, a Death Star prop about 5 feet in diameter or so.

I've been doing some small scale tests with paper mache and such, but my core problem is how to create the armature/framework upon which it will be built?

My only condition is that I have to retain the ability to access the inside in order to have it backlit. I'm planning on drilling pinholes through surface to light from behind, ala Star Wars.

I've contemplated chicken wire on the outer surface, but I keep coming back to my core problem--how to concoct a sphere and/or curved ribs around a core frame. And what that frame looks like. I keep running into basic overengineering issues here.

Any ideas, suggestions are greatly welcomed! Thanks!
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Check out the tutorial here on making witch cauldron. My wife and I made one last year using cardboard spars abound a plastic tub. With a little modification you can make a ball using this method. We doubled the amount of spars to lessen the facet effect and then I rounded it out with paper mache clay as you did. By using the extra spars it required less clay therefore less weight. It was still a lot of work, a lot of drying time and it got heavy. But it did work. When finished I gave it three coats of truck bed liner for protection. Here is pic of it so that you can see the roundness we achieved.



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