Building a Prototype for a 6' Hexayurt from Kingspan Metal Sided Sandwich Panels for Winter Storage use to Bear a Snow Load
Please Note: at this stage we are experimenting with loose ideas from off cuts of older metal sided Kingspan brand rigid foam sheets & reused drywall framing
We decided to have a go at this. There are over 30 Hexayurt designs. we started with the smallest for practicality
Given a potential virus caused economic depression & further crisis with a lack of low cost / easy build shelter for temp housing / work space / storage perhaps Hexayurt designs will become more popular
We first cut and propped the 1m x 1m + size kspan sheets (80mm thick wall & 45mm thick roof ) and propped them up to explore ideas
The First idea was to have an enclosed gutter & raised edge (this was already on the offcut panels edge) The thought being that this would hold snow on the roof in winter as extra insualtion . However a very good seam seal would be required to stop leaks to inside
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzXrXtd1q_OffwHdSCCf4T5N23pH5OGNLmu3J2r-BKqeAtDcLntEPhmUOAxYVNoPwTykh9fQf9-wX3LVTxOgLtgB-EyuXtFccT_s6Hp53loqlzSw44_ocHOQDgcbkw8VEW4HO47rgM9FQ/s320/20200709_172114.jpg) |
Wider pics
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhYBo-KMAg9_TxN-b3xCEdcmN_PGbafeYVZZQfMdWBddaYheOcj6rDGSUVVpAqTL-gCc9-UN9EKzd2fT_sspUmANeGS5hN8R6T09PyO-q9Ctv-LY7zATa3cSWoX7DuhulzOmgGS68P3aOw/s320/20200709_172155.jpg) |
Close up of roof seam , cut straignt at first
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiG-1CZRKgEOc-CcML-bIA8XBgGDEwZDMCKeTXksipgBOkH68k3TYuT4iVvQHn8EXFz0R22wx1r5oxxkLOrvdVIc3ACQVS1SGlAW5E-OAEWC64-3y0PEV6_XTabRVkG1rXAKTAUFG-zBTo/s320/20200709_183430.jpg) |
Top edge was cut off to make it flat against the foam end and drwall frame I beam laid on top . Folded edge on one side, useful for fitting to wall. perhaps with drywall frame I stud as shown in pic (146mm wide )
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2ys7Euamdvf6bePHqPft50hzBX2YEycxEgq14NVnxdF9blNWHCnfGdyHb6baJS1LRewzZmtitqB1nSu0H3Qkfcw-JvnzmOYJQh6ymP7zINnYZg154olfI32jnIoqqbWkSeZIUm5oYaB0/s320/20200709_184040.jpg) |
146mm wide I stud on top of wall is too wode , but if wall was cut at an angle to mount roof, it would fit more tightly
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghit222H5sJJ6tW7nF0idPE3kDibvLvfNEWJxvljdt7FnwTsOW0FfT46j0XLEXVLXhUkOOF-oZ_1zgOXRXeSV7LYr4Z_z5f1yEg6qwd1yDMT-ZBhPqrps6KlXFx_dYmm9vOmsDfaHpHas/s320/20200709_185419.jpg) |
lay up of 2 longer wall drywall studs (92mm wide) scrwed back to back to form dee pwall I beam for joining roof sheets
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjDlfNMtv1fyQIrrcpYAG3jy-4kbip_mBbuyQtRipP_6lFUPOohL50tl43mOsKyt4JyZYoQ_7F555S8_eI3mW3w0HHalww50vHPAQFT430d0-Dh86TjvU3fE8ISdM0W6PjuuXxZn0CMMVM/s320/20200709_185658.jpg) |
Wider pic
|
Cttting & fastening wall panels together
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9XrlNBSvBusevL56wNvmKrVl6dI7h4FmJUxp8iUoNm4B2I2NNMpLk29DbJHFYQnoi3KJ4l3J0GW_v4aEM7Qk_KRzbj2W4Ozvv-Qy2zAxj-KINfidhEfJw6qMOx6R_-jKQQF7h6LAVaYM/s320/20200710_131836.jpg) |
Peel steel on inside away from foam by hand & cut by hand with sharp kitchen knife
Note: a thin strip of folded metal had to be cut off the edge
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsh4hc8alDrhEeJwl9adtTc6ZNvl_4fDhc4cLf9Ex329eqGTLBg8d6R1R6A1jeHDhlwq0CCwPgWjehqgLfY2XQumpytDbtkvp9giR0-hEmSyFCQymMQ8a0DNZ6BXs8Mhl79ihxM0sYA4Q/s320/20200710_131846.jpg) |
Marking shown |
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjw07qp-sQ0Sy6mfG1K8G1WN5sEB_VSGNNAZdoW5lXiFzz-WZHkHwhH-eOEFBu0UYxorMQiAGW8pltpitt27EhRFREIdKKBc19vfHdKgW2075FJoGp6y1ngxe25WM-jKY0Or4i9Grcp6t8/s320/20200710_141607.jpg) |
Method shown for bending metal along supporting metal bar
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJRwpDkGcirxGPIcEiNaEvuvJEL-m58whmnx2Zk_7jOeqrnh4SG7y33bDv7als85rN8ZFhR0cPyi0V2lmdrx7mLTKG1WVoByWPyO9LaRe46Lf8W4QtDBMTVfkw8sGWcCQdf-cit_ZJH78/s320/20200710_141708.jpg) |
Wood used to keep it straignt when pressing down
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyiunO5ecc_wOPkWaL4hiZMGJpMV6i3lLxkqHCkyuGG00i4cArLn3YwjBhR-zVU17tNqTDI6HwGep7YCAgeZtuoGmGdFnaKlucMhX3kYxLvkaXbwoi-cQv07VQrizp70qzkpB3tw1Sjmw/s320/20200710_141725.jpg) |
Finishing by hand
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeDXy_TEsFjOQxn1O1WwxFwaGhLw_6J0VL8Ask0AuaC4fSkJOLdiWcTBaOdX2aj9KDHkx1i-swj5x94KCPdd8MuCQrcwAM9_oE_v7ixjuzFaAI2u_jsF1o1V32D4Wfw9ov6FsxgjyzOuE/s320/20200710_142300.jpg) |
Top view of seam with meatal bent, ready to be screwed in place
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFb1MSVB4AuNLjWTpoIzEvdVxoGobEukjCybG08HR_K-Z99Ydp7FGjMM0t6iWoBsVtw897VBg8gFSHPbxqkQxs-38qOrINdZwboofDgvAZlVccGG1q6PiL4vs-OzqFavDtQXoSG9CTMnE/s320/20200710_142310.jpg) |
Inside view
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNNQyMC4mXfxwXsGlz3wW1Gu2yVZwifPCu7ds0yHjI1QCxlqyNhL7vDKZf_UJ_rc53Eih_3xfh7YcLm4nq7NGIH4MJIkn-GmY8bIMiUW8PLjce8IEpMII6vsh2Oui1J0Zlalf-ZjEuVxI/s320/20200710_142317.jpg) |
External view Note: After cutting & bending, it was a great fit, utilizing the exisiting overlapping flap
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioqshb6bbwh-YnRasGCaZ7xyMyEzBMGJarkSK1mI38valxR5LvYYKoPz0h8zvCviCTDX6Vy_2pwfEVsje3GonfNu7hZh0Kd52d4wVDhhqDKOD2b5k2BgWra1_prneYGWFrqnUU3WwuZ3w/s320/20200710_144030.jpg) |
Screwed im place with 3 rows of self drilling flange head screws inside & out
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEioLaIu4JMzlbU9AcSrDPkpF-voepKfWnXsGEGEYrqIoArKNYbi6GZY6qIp0kV9t86EcERXrn5_5MgeoOsnnLkZ9N6h-7zBDt7ag55RC3RVg62DK0xf2RgmK6k0foovdaicuAcp9ZMSK_Q/s320/20200710_160532.jpg) |
A 92mm drywall frame stud beam was cut & bent ove the wall ridge to cover the top awaying connection of the roof panels
|
![](https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuQsEGxvoa1E9U3FVUlE3C7KqajbxfIa1-iIQ-Ax16XIP8QGP44lKSCjs_qNwlLYdcJdebul-dMRjVZX4LjH-h_2QZ-SMYi958SNufB9AT06QGUk2pi-FKKT67g_FFv89UTYPBL13pSs8/s320/20200710_160541.jpg) |
other top views of top plate
|