This is the assembly of my Megamorphix puzzle, for the design process see Part 1.

So, I've sent off the design files to Shapeways, and while I'm waiting I can do the 4x4x4 cube truncations required. Fist tape up the cube to keep it nice and stable for the cutting - this ensures all the cube faces are square and stops the cubies from moving.I mark the cut lines in pencil, and using a razor saw I cut along them carefully.The cutting is too rough, so you must sand the cut face smooth. During this process I sand about 1mm past where the "ideal" cut lines are, to allow for the design of one of the extensions. Also, because the corner pieces are in two parts, and the cut separated them, I had to disassemble the cube so that I could glue the truncated corner piececs back togetherThis is the finished truncated cube.I wait a couple of weekss and, behold, a parcel from Shapeways arrives.As usual, the surface of the pieces is covered in a layer of fine powder, which I clean off using a wire brush. This is what happens to your shirt when you are finished.I'm not sure how unhealthy breathing that stuff in is These are all of the pieces sorted, and they were all present and correct. There are 5 different types plus some small caps I had printed so that I didn't have to cap the truncated corners myself.Note the piece in the bottom left corner of the picture above. The two pyramidal shapes are connected by a flat face. This was not absolutely necessary, but I thought it would look neater done this way, otherwise I would have had to glue on the two little pyramids separately. This is the reason for sanding the extra 1mm.

This is the stuff I use to dye the pieces: Rit dye, white vinegar, washing up liquid, a colander and a spoon.I also use this pan, and I usually put this in the bottom to help bubbles circulate and to stop any pieces touching the hottest part of the pan.I clean the pieces in hot water and a squirt of the washing liquid, and then thoroughly clean them in lots of warm water (including the insides of the pieces.Now I add a spooful of Rit dye to hot water, a drop of washing liquid (to help the nylon parts sink) and a cap full of white vinegar.At first the pieces are definitely not black, but after 20 minutes of boiling and stirring ... After drying, I can glue the extensions onto the truncated cube. But first, I rough up the surface of the cube using a steel brush, as this helps the superglue work.In the next picture you can see the brush I used to clean up the 3D printed parts.Finshed!I designed the stickers using SketchUp and made proper dxf outlines for the faces using Visio. Off to Dr. Sticker with them and wait for the very slow postal service to deliver them, some careful placement ... Checkerboard pattern.Scrambled.Full scramble.Well, that's all folks! Hope you enjoyed reading about my puzzle building efforts, I hope it inspires some of you to do your own someday.

Incredible. I really hope you sell this on ShapeWays.

-Doug

Heh, I had bought the mini 4x4 planning on making a mini Megamorphix. I guess it's a good thing I decided to make something different.

Awesome work, looks very nice!
I have three questions
1. Will you be offering these at Shapeways (as I don't have the required software and experience to design it on my own)?
2. Would it be possible to seperately upload only masters? That would make it cheaper and I would like to cast pieces anyways.
3. What is the size of the puzzle?
Thank you!

The edge length is 130mm and it weighs 130g. Coincidence? I think not

I could put these up on $hapeways, but I have to admit to a problem. I did not bother to adjust the 4x4 before I glued on the extensions and the turning is poor. The 2x2 turns are OK but the outer slice turns are very awkward. I don`t know if this is because the correct tension has not been applied or because of the design of the extensions. I will try to take it apart and re-tension the 4x4 and report back.

HAHA this is pretty awesome!

i really hope this is put up onto shapeways, it would a much cheaper alternative to a handmade one for sure

Once you do place it on shapeways, I will be sure and order me a set. My adventures with plastic sheeting have not gone on like I would have liked them to have. I would love to have a morphix set from 2x2 all the way up to 11x11..... one day. One day.

Fantastic! Thanks for the detailed post.

Dave

*** BUMP ***

Sorry for the long delay since my last post, but I've finally put up the add-on pieces on my Shapeways Shop.

I have to say that correct tensioning and lubing of the mini 4x4x4 cube is essential to make this work well. I didn't do this, and my puzzle can be very frustrating to turn - and now the pieces are glued on, I cannot change the tensions

If anybody buys the parts, I hope you will post your story in the forums.

Yes! Finally! Thank you, Gus!

-Doug

Gus, I only just saw your original post. Absolutely brilliant! Thanks so much for posting all the photos of the along-the-way stuff. Wonderful

well, like i said, you put it up and i will get it.... just ordered the set. should be here in about 3 weeks give or take. once all the pieces arrive i will post pics of the process and how it turns out.

thanks man!

well the extendy parts are here, just waiting for the cube to arrive.

this will be fun. i will be doing a 5x5 as well....

Good luck with both puzzles. Remember to use strips of paper between the pieces to help stop the ingress of the superglue. It is easier to remove the paper and clean up the parts with a scalpel than to un-stick glued plastic pieces.

okay, the cube arrived a few days ago... so on to building and modding. I will post some pictures soon, since I left my phone at work..... anyways... it looks wonderful. But, like I am sure you had, there are issues with the underlying cube. I will get in to those once I have the pictures to post.


I like pillows.....

well, the cubes arrived. the pieces are there as well. i got the moster built up and thought it was tuned correctly...but pieces inside and with corners broke off.

Do you mean the corner cubies broke off, of the extensions broke off the cube?

the inner pieces of the 4x4 snapped. a few of the middle pieces and the corners snapped off. more or less my doing i guess. once it was complete it looked great. then i played with it a bit too rough. soooooo i basically made a morphix a mini 2x2 i had. the rest are sitting in the parts box for when i decide to fix up a 4x4 again.

Oops, that's a sad end to your efforts The mini 4x4x4 is indeed a poor choice for this type of puzzle, I thought that maybe one of you guys would be able to lube and tension it to make it better.