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The Icopod arrives on a pallet (1 of 115)
Pictured in front of the Mackinaw Mill Creek Camping "Fun Department Truck" is the entire Icopod boxed up and on a shipping pallet.
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Terry and Pam Morrow begin assembly of the Icopod (2 of 115)
"Exercising" the seams is the first order of business when assembling the pod. Pictured here, Terry and Pam Morrow, Mackinaw Mill Creek Camping staff members, begin assembly of the "Pod."
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All pieces of the Icopod are flat before folding (3 of 115)
Pam and Terry are pictured using the shipping box as a clean surface to fold the Icopod pieces on. The folded finished pieces are shown stacked behind them.
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Folding one of the main seams of the Icopod (4 of 115)
Pam is folding the "pre-exercised" plastic piece. Having Terry to help hold and fold make things much more manageable. Assembling an Icopod with one person might be possible, but would be very, very difficult.
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Folding a piece of the Icopod, Step 2 (5 of 115)
Shown here the piece takes shape.
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Folding a piece of the Icopod, Final Step (6 of 115)
Shown here Pam and Terry Morrow have completed the first step in folding the pieces.
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Repeating the Icopod folding process 42 times (7 of 115)
It takes 42 of these main pieces to assemble a completed Icopod. Although the larger Decapod takes a crew of 10 people around two days to complete, it uses the same basic size pieces - just many more of them.
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Side view of completed Icopod panel (8 of 115)
Here you can see the side panel with nearly all of its tabs and folds made. At this stage bats of insulation could be slid inside or blown in. However, we are going to use the natural "trapped airspace" of the Icopod for insulation as ours will only be inhabited during the temperate months here in the Straits of Mackinac.
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Creating "triangles" using Icopod pieces (9 of 115)
Shown here, Terry and Pam are taking three of those support pieces and sliding them together to create the triangles that make up the main geometric structural shape that gives the pod its look and strength.
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Creating a triangle for the Icopod, Step 2 (10 of 115)
Once the pieces are all lined up, the tabs are inserted that lock the pod into place.
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A nearly completed Icopod triangle (11 of 115)
Once the tabs are folded in the triangle is completed.
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All of the 42 pieces are made into these Icopod triangles (12 of 115)
Pam checks the Icopod manual before starting to join the triangles together to create the "cap" of the structure.
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Icopod trinagles attached together (13 of 115)
Pam and Terry begin ataching the triangles to each other for the cap.
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The Icopod triangles lock together and the "cap" takes shape (14 of 115)
Five of those triangles are linked together to create the roof of the Icopod. Terry and Pam stand in the space that will fold in as they pick up the triangles. The last tab will then be inserted to create the shape of the cap.
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Close up of some of the Icopod's locking tabs (15 of 115)
Various shapes and sizes of tabs are used to lock the Icopod structure together. All are die cut from the same flat piece of recycleable plastic and folded into shape.
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The Icopod cap is large, but lightweight (16 of 115)
Even though the cap will be very strong when completed, the actual parts are light enough for two people to lift.
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Getting ready to spring up the Icopod cap (17 of 115)
The assembled pieces will be lifted from the center and will fall together to lock into place.
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Lifting at the top of the opening and the Icopod cap is up! (18 of 115)
Terry and Pam both stand in window openings and pick up. The triangles slide together to close to a five sided cap.
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Taping the pieces and seams of the Icopod cap (19 of 115)
Terry and Pam are shown here taping the seams and window openings. The taping will seal the gaps and is very important to the final structural integrity of the Icopod.
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Assembling the Icopod's base ring and its collar (20 of 115)
Pam and Terry are folding the collar that goes over the base ring. The base ring with its collar supports the walls.
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Assembling the Icopod's base ring and its collar (part 2) (21 of 115)
The Icopod base ring and the collar for it (pictured here) one of the more challenging parts to assemble. It is why it takes a minimum of two people to assemble the Icopod.
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Assembling the Icopod's base ring and its collar (part 3) (22 of 115)
Here is another view of how this part must be puckered, which takes a bit of help from a second person to accomplish.
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Attaching the collar over the Icopod's base ring (23 of 115)
The first piece of the collar is applied over the base ring. At this point, the "pucker" collar wants to spring back so having a second set of hands is crucial.
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Attaching the collar over the Icopod's base ring (part 2) (24 of 115)
Here is another angle of attaching the collar to the base ring.
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Attaching the collar over the Icopod's base ring (part3) (25 of 115)
The assembled color pieces are waiting while Pam and Terry seat the initial piece.
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Attaching the collar over the Icopod's base ring (part 4) (26 of 115)
Close-up of a side view of the collar over the base.
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Attaching the collar over the Icopod's base ring (part 5) (27 of 115)
The first piece of the collar is firmly in place and now Pam and Terry will continue doing the same for each segment of the base ring.
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Setting the triangles of the side walls into place (28 of 115)
The triangle pieces of the walls are fitted together by pairing the slots and tabs (visible here) and fit together like puzzle pieces. They rest on the collar held in place by gravity until they are taped together.
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Taping the seams (29 of 115)
One of the most important tasks is carefully taping the seams. The tape must evenly overlap seems and be firmly burnished into place.
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Taping the seams (continued) (30 of 115)
The tape for the Icopod has gone through many incarnations. It needs to be waterproof, and to hold firmly to the plastic walls. Technology that goes into emergency repair tape for sails comes in handy here. The tape is thin and takes some time for us to learn to handle efficiently.
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Inside view of the assemble triangles for the walls (31 of 115)
The side walls lean in and gravity holds them into place, so no tape is required on the inside of the structure.
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We assembled our Icopod in the campground's Rally Building (32 of 115)
We chose to assemble our Icopod under the structure of the campgrounds rally building. This kept everything dry and made it easy to tape without having to worry about condensation or morning dew.
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Having a second hand helps immensely with the taping chores (33 of 115)
Getting a straight bead on the tape and keeping it from adhering to itself is nearly impossible without help. We cannot let the tape touch itself or it will become irretrievably attached to itself.
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Working the seams (34 of 115)
Before any of the pieces are folded, you need to "work" or "prepare" the seams, which is accomplished by flexing the plastic both ways.
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Unused pieces are cut and used to cover exposed corners (35 of 115)
Once the triangles of the sides are in place, there will be a corner on each side that will be exposed with its tabs open. These are covered with triangles that are cut from the edges of unused pieces.
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Liquid nails used to adhere the corners (36 of 115)
We used liquid nails adhesive to help hold the pieces patched over the corners. It held well, but showed through the plastic. Since we plan to paint the exterior with an elastomeric UV resistant coating we knew this would not ultimately show through. However, on our latest icopod, we used white and transparent adhesive for this purpose.
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Fitting the slots into the tabs (37 of 115)
As with everything, the tabs fit into slots that help hold them in place. Here I check the fit of the next corner piece before applying adhesive. Most of the structure is held in place by gravity. Taping it helps secure everything into place, and waterproof it. However, the ingenious design makes gravity the main force that holds the Icopod together.
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Doorway corner pieces (38 of 115)
Taking the place of the triangle that is missing to make room for the doorway are two slim triangular pieces that go on either side of the doorway.
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Doorway corner pieces (continued) (39 of 115)
Another view showing the slim triangular pieces that will go on either side of the doorway.
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Fitting the doorway corner pieces (40 of 115)
Here I am checking checking that the assembled doorway triangles are fit into place.
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Preparing to move the assembled portions to a campsite (41 of 115)
Not everyone has a big tractor with a flatbed trailer, and crew of people to help them, so assembling your Icopod in this way may not be practical. However, with Michigan's unpredictable early spring weather and temperatures, this worked well for us.
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The crew discusses moving the base (42 of 115)
Until the entire Icopod is completely assembled it is quite fragile. Because of that, it takes a number of hands to keep it balanced as it is lifted and moved.
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Everyone takes a side (43 of 115)
Our crew evenly surrounds the Icopod. Many of our staff are seeing the Icopod for the first time. So acquainting them with it and what we are doing takes a bit of discussion.
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Lifting the Icopod onto the flatbed (44 of 115)
The Icopod is very light, so with a person on every corner everyone is only lifting a few pounds. It is the geometric design that gives it its strength, so weight and heavy materials are not necessary. Everyone lifts and it is easily put onto the flatbed trailer for moving.
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The Icopod cap is placed on a trailer (45 of 115)
The cap of the Icopod is very light, but the protruding flaps which will attach it to the walls have to be accommodated when lifting and moving.
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The Icopod cap is positioned on the trailer (46 of 115)
The Icopod cap not made to sit anywhere except for on the side walls, so there has to be taken when situating it as even its own weight can be too much for if it is not balanced evenly.
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Loaded and ready to go (47 of 115)
Since we are only traveling a short ways, at slow speeds on private roads, there is no need to fasten the base of the structure to the trailer. Luckily there are no winds, or this would have been much more challenging.
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Navigating through the park (48 of 115)
The trip to the final resting place of the Icopod was not without its challenges.
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Clearing the trees (49 of 115)
With a bit of help, the Icopod clears the tree branches and we are on our way.
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Checking for damage (50 of 115)
Without the cap in place, the structure is not able to withstand much stress, so even tree branches brushing it on the side could knock do pieces out of place.
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Re-seating the walls and doorway (51 of 115)
Making sure all of the pieces are properly seated after the brush with tree branches is important so that the moving structure would have as much support as possible while being moved.
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On its way (52 of 115)
With the walls and doorway check for positioning and seating, the base of the Icopod is on its way.
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The Icopod cap leaves the building (53 of 115)
The Icopod cap easily clears the tree branches on the way out of the building.
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The cap’s protruding flaps make it a bit ungainly (54 of 115)
Though lighter and easier to handle, the ungainly flaps make moving the roof a delicate operation.
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The cap moves through the campground (55 of 115)
Here the Icopod cap moves through an undeveloped part of the camp on its way to its site.
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The concrete base for the Icopod (56 of 115)
With many talented concrete tradesmen among us we were more comfortable with creating a concrete base for our initial Icopod. Just recently, we created a wooden base for our newest Icopod. Here you can see the base ready and waiting.
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The base moves through the camp (57 of 115)
Nearing the Icopod’s new site, here you see the base moving through the camp.
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The crew follows the base of the Icopod (58 of 115)
Due to the fragility of the incomplete structure, the tractor moves very slowly. The watchful crew follows.
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Backing the base unit into place (59 of 115)
Remember, all of this moving and extra work is unnecessary if you build your Icopod in place.
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The crew each grabbed a corner (60 of 115)
Again, each crew member grabs a corner so that the unit is picked up evenly.
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With no wind the unit moves easily (61 of 115)
The unassembled Icopod is very light and is easily lifted and moved by our crew.
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Lining up the base Of the Icopod (62 of 115)
The crew lines up the base of the Icopod with its foundation.
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Lowering the Icopod into place (63 of 115)
The base is easily positioned onto its foundation.
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And it is in place (64 of 115)
The unit is set into place and checked for positioning.
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Adjusting the position (65 of 115)
The staff makes some last-minute adjustments before fastening the Icopod into place.
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Applying adhesive between the base and the foundation (66 of 115)
We chose to put a ring of liquid nails adhesive between the bottom of the Icopod and the foundation.
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Final positioning of the base (67 of 115)
The crew places and gently presses the base onto the foundation so that it makes contact with the adhesive.
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The Icopod's cap arrives (68 of 115)
The base is now ready for the cap, shown here arriving at the site.
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Backing up the cap into the site (69 of 115)
The cap is backed up into the site. It is, however, very light and could be lifted into position without backing it all the way into place.
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The crew organizes for the assembly of the two pieces (70 of 115)
With both pieces of the Icopod now at the final site, a discussion ensues on the best way to join the two pieces together.
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Creating a plan (71 of 115)
The crew decides on the best strategy for lifting the roof into place.
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The window opening (72 of 115)
The plastic windows of the Icopod are not yet in place, but will secure the remaining openings against wind and rain, and allow natural light.
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Consulting the assembly manual (73 of 115)
I go over the assembly of the windows and vents with Pam and Terry.
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The doorway (74 of 115)
Since our Icopod will be rented to the public, we decided to reinforce the doorway with plywood. Due to the structure of the unit, there is a sizable edge that must be stepped over when entering the icopod.
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Another angle (inside view) of the doorway (75 of 115)
This plywood will be painted white, and will protect the inside of the doorstep.
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Beginning assembly of the vent (76 of 115)
Window screen is prepared to be attached to the vent that will cover one of the open "window" triangles.
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Windows are attached to the roof before putting it into place (77 of 115)
The plastic windows are folded and snapped into place on the roof. Weatherstripping helps make a tight seal between the Windows and the Icopod.
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Window in place (78 of 115)
The final window on the roof is put into place.
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Attaching the vent (79 of 115)
I put the assembled vent into place on the roof.
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Roof flaps (80 of 115)
Close up of assembly flap that will attach the roof thatto the base.
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Screen over window vent (81 of 115)
An upper and lower event help the icopod to circulate air naturally. This is a close-up of the incomplete lower window vent.
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Lifting the cap (82 of 115)
The crew lifts the cap of the icopod from the trailer.
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Hoisting the roof up (83 of 115)
Raising the cap into position.
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The cap goes up and up (84 of 115)
The crew raises the roof to clear the base of the unit. Picnic tables and the flatbed trailer served as a makeshift scaffold for us to stand on.
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Positioning the roof (85 of 115)
The crew positions the roof over the base and prepares to put it into place.
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Clearing the flaps (86 of 115)
At this point the biggest challenge is keeping the flaps out of the way when positioning the roof onto the base.
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Nearly in place (87 of 115)
The roof is nearly in place. Like a puzzle it won't fit perfectly until it is exactly in position.
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Slightly adjusting the position (88 of 115)
As you can see the edge in front is fitting closer and the rough is nearly in place.
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Gentle adjustments (89 of 115)
Gentle adjustments are made as the roof fits into its final position.
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Finally in place! (90 of 115)
As you can see now the roof seems fit tightly to the rest of the unit. The flaps that extend out from it will be fitted into the base unit to anchor the roof.
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Sliding the roof flaps into the slots on the base unit (91 of 115)
The crew begins sliding the roof flaps into the slots on the base unit. You can see one in place over the doorway is it is bowing slightly. It will need to be taped into its final position.
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Applying tape on the upper seams (92 of 115)
Now that the roof is in place, it seams need to be taped.
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Painting the surface (93 of 115)
With the Icopod now in place, the entire surface is painted. To avoid UV damage, we painted our Icopod with elastomeric UV resistant roofing paint.
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Taping the floor in preparation for dying (94 of 115)
We decided to dye our concrete floor to make it a bit more appealing. Here, Sarah tapes off segments of the floor that will be dyed first.
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Close-up of taping (95 of 115)
Sarah is leaving small bits of concrete exposed which will be coated with sealer first so that they will appear lighter when the floor is dyed.
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Taped pattern (96 of 115)
Irregular strips will be coated with sealer first. You see some of the irregular strips here that are exposed inside the tape.
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Texturing the dye (97 of 115)
Here Sarah uses an old pair of blue jeans to absorb the diet that has been applied. This gives it a bit of a rag or sponge blotted type of a look.
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Blotting the dye (98 of 115)
Sarah works the wet floor with the blue jeans. You can see in the upper left portion the effect that she is attaining.
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Patterns in the floor (99 of 115)
You can see one of the lighter irregular lines that was created when Sarah applied this sealer earlier - in the upper right corner.
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Appearance of the pattern (100 of 115)
Nearly done, even though the dye is not yet dry, you can get an idea of what the final appearance will be.
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The floor before sealing (101 of 115)
You can see as the dye dries the pattern that will emerge. The blue tape protruding from the floor covers conduit that brings electricity into the Icopod. The floor will be sealed which will give a gloss after the dye has cured.
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After the sealer has been applied (102 of 115)
The floor darkens in has a gloss to it after it has been sealed. If you stay in our Icopod today, you will have a wooden floor. We attempted to move this concrete base when we relocated our Icopod to a new site and it did not survive the move.
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Final view of the sealed and dyed concrete floor (103 of 115)
A last look at the icopod floor after it has been dyed and sealed.
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Inside view of the Icopod (104 of 115)
Here is an interior view of the Icopod. As you can see it is quite beautiful for a structure made out of something that resembles a plastic FedEx box. Natural daylight gives even lighting that would satisfy an artist painting on an easel.
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Inside view of the Icopod (continued) (105 of 115)
The cavities in the side walls act as natural insulation due to the trapped air. However, during assembly, if you require more insulation be cavities can be stuffed with fiberglass insulation, or if you are in a remote location even grass and leaves would do.
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Amenities inside the Icopod (106 of 115)
Our Icopod features a queen size bed, ceiling fan with a light, microwave, and small refrigerator.
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Amenities inside the Icopod (continued) (107 of 115)
Here you can see a better view of the refrigerator and microwave as well as the floor rug.
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Finished external view of our Icopod (108 of 115)
Here is a view of our completed and assemble the icopod just before painting the exterior with the elastomeric UV protective paint. You can see the tape on the scenes. This picture shows the wooden door we built in place of the plastic door that comes with the unit. We replace the original one because wanted our campers to be able to lock their door. On our latest icopod we have actually created a wooden entryway.
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Finished external view of our Icopod (continued) (109 of 115)
Here you can see the structure sitting on this concrete base with the wooden steps that we built for it.
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Finished external night time view of our Icopod (110 of 115)
The windows give off an beautiful glow at night and the Icopod takes on an otherworldly glow at night.
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Finished external night time view of our Icopod (view #2) (111 of 115)
Another idea of what our campers see when walking through the park and seeing our Icopod at night.
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Finished external night time view of our Icopod (view #3) (112 of 115)
Along with providing excellent daylight lighting, the concave white surfaces inside the Icopod make a little bit of light go far. Just one light bulb gives satisfying illumination inside the Icopod at night.
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Finished external night time view of our Icopod (view #4) (113 of 115)
We have been contacted by both FEMA and CNN about our Icopod which was designed to be a humane structure for disaster relief and the homeless. Much of the world’s dispossessed sleep in tents if anything, after a disaster or if you had lost your home, which would you rather live in, a tent or an Icopod?
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Finished external night time view of our Icopod (view #5) (114 of 115)
42 million people were left homeless due to natural disasters last year. If the Icopod was mass produced it could literally give everyone a safe nearly permanent home. We have had an Icopod standing for over 7 years in the severe northern Michigan climate (humidity, high winds, extreme winter storms, blizzards, high snow levels, heavy rains).
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Campers learning about our Icopod (115 of 115)
Everyone is curious about the Icopod. So much so that we needed to ask campers not to disturb our guests occupying the Icopod. We erected a sign to help answer questions. To learn more about the Icopod and the larger Decapod go to http://foldedhomes.com
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