I sourced some super cheap chopsticks from ebay and set about making my own slight variation. I knew I could not use exactly the same design as the chopsticks where not hexagonal cross section like pencils and they tapered. So rather than the 72 pencils of George Harts original creation - I went for 76 chopsticks in a solid three to the edge hexagon rather than empty 4 to the edge
Step 1: Craft Temporary Rigs I
1. To avoid ripping paper make a tiny cross cut in the board (much smaller than cross section of the stick) at the point where the tow lines meet.
2. Supporting the board push one chopstick through
3. Lie a chopstick flat on the board and ensure it is point at around 60 degress
4. Draw around a second upright end of chopstick
5. Repeat with another to get a good idea of the separation needed.
Step 2: Create Temporary Rig II
Step 3: Create Temporary Rig III
Step 4: First Dimension
As the chopsticks are not the same down the entire length (ie they taper) it matters which way round they are I decided to have all the corner sticks in the same direction and those in the middle of the side in the opposite. The ones in the centre I alternated direction.
After the six corners and the centre I added the other rig and gently pushed through the others. You should end up with nineteen chopsticks held firmly in place by the board rigs at each end. You can note from the photo that there are clear gaps through which you can see/stick next set of chopsticks
Step 5: Second Dimension
Up close you can see that another set of holes that the next dimension will fit through.
Step 6: 3rd Dimension
Step 7: Into the 4th Dimension
After the last set are through (which I forgot to photo) - put elastic bands around the end of each group (I managed to photograph that) and very carefully remove the rigs.
Step 8: Remove the Evidence
Any of the interior that are loose can be fixed - by giving a little twist. As they are square the twist will tend to lock them in place
Then a thin band of see-through acetate (I used a hacked up cover of a presentation folder is wrapped next to the rubber bands and secured with a small bit of see through Scotch Crystal tape. Do this for all eight ends - before removing the bands. As the tension is released from the bands then acetate strip with take the strain and be held tight.
This is almost invisible - i have tried to get a snap of it. Mostly you can only see it when the light reflects off.