I wanted to do something with plastic CD's besides adding them to the land fill - My solution was to use them build 3-D geometric constructions. I describe here how I used 12 CD's to build a Dodecahedron. I also built a 32 CD trucated Icosahedron, 12 of the CD's must be cut smaller an that takes a lathe,.
Step 1: Materials and methods
1. CDROMs are made of Lucite (acrylic)plastic
2. I connect them by gluing 1/2" sections of flexible lucite hinges purchased from Tap Plastics - $1 for a 12" hinge. 25 joints are needed so you need at least 2 hinges.
3. The glue I used is "WELDON #16 clear, thickened cement for acrylic" Also purchsed at Tap.
4. A single dodecahedron "ball" is constructed in 2 halve of 6 CD's each using a layout jig I will describe.
Step 2: The Gluing Jig
The basic idea for each half, is to place a single CD in the center surrounded by 5 others so that the hinges can be glued accurately and simply. I used 6 "pegs" on a 2' by 2' piece of plastic or plywood. Drill a 3/8" hole in the center and 5 others at exactly 72 degrees apart and 4 13/16" from the center. The CD center diameter is 9/16". This is not a common size so my solution was to make the center pegs from 3/8" dowel with 3/8" ID clear Tygon tubing slipped over it. You can get both at any hardware store. I use a CAD program to lay it out, but you can also construct it on paper with a compass and protractor. Accuracy is important!