I started out thinking I could use flexible hinges and the geometry of the piece would keep it rigid. That didn't work I think due to the fact that much of the surface is pretty flat and I think I would also need some kind of frame to constrain movement. Since the easy way didn't work all the connectors have to be bent to specific angles for the assembly. With a jig and a system this went pretty fast. It took me (with Amy part of the time) three full days to assemble about half of the piece. I will make it up into the biggest pieces that I feel comfortable transporting to leave as little assembly on site as possible.
Bending jig:
I have to keep all the pieces organized by angle or there is major confusion. It is really hard to tell the difference between a 3 or 5 degree bend when they are lying on the table but it makes a big difference in the assembly.
I calculate I will need about 800 connectors and 1600 screws to assemble the final piece.
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