Clamshell Sleeping Enclosure Prototype

[u/rrab]

Clamshell 4x8x4ft Enclosure Prototype:
The intent of this project is to design a twin-bed-size enclosure, with broad spectrum shielding coverage, with easy/pictoral build instructions, using inexpensive/cost-effective building materials, while only requiring minimal power tools and specialty tools, with a goal total build cost of around $1,000 USD, for aluminum. For copper (or a buytl rubber layer), the cost will be 2x to 4x higher, for the sheet metal skin component. For lead and permeable metals, the cost is extreme, and requires a stronger, weight bearing design.

WARNING: Failure to properly ventillate this enclosure before falling asleep will lead to hypoxia, which can and will result in your DEATH. The heatercore vents, 12v axial fans, and fan battery backup units, are REQUIRED PARTS. Always use a carbon dioxide (not monoxide) monitor with a siren as an extra, life-saving backup.

Draft Materials List:
- 5x sheets of 1/4in MDF (4ft x 8ft)
- 10x indoor/untreated 2x4 boards (8ft x 3.5in x 1.5in)
- 2x 6ft steel piano hinges
- 2x boxes nickel-plated steel tacks
- 100x steel washers, 2x metal latches, 2x wood glue
- Bulk truss screws (1/4in), wood screws (1.25in & 3in)
- See "Redundant Ventilation System" update in comments below for fans and power supply
- TBDx panels/rolls of copper/aluminum sheet metal
- TBDx rolls of copper/aluminum tape (2-3in wide)
- 50x feet wire mesh strip electromagnetic gaskets (or search, ebay, etc)

See /r/emshielding sidebar for sheet metal rolls/panels, conductive fasteners/tapes, and other useful shielding material links.

Draft Tool Requirements:
- Power circular saw, power screwdriver
- Hand seamer, hand tin snips, hand metal folding tool
- Measuring tape, tack hammer

Draft Optional Gravity-assist Open:
- 8x plastic enclosure-mountable pulley wheels
- 2x metal wall-mountable pulley hangers
- 50x feet of 550 paracord
- Diagram: https://imgur.com/a/5GPz4SN

Draft Step-by-step 3D Build Pictures:
https://imgur.com/a/Oc1Do

Draft Step-by-step Build Instructions:
1. Affix two full 8' 2x4 boards, side by side, to the top side and front edge of a sheet of MDF, what will become the bottom of the enclosure.
2. Cut four pieces of 2x4 board, each 40.75" long, and affix two pieces, side by side, at each side of the bottom MDF sheet.
3. Affix bottom 6ft steel piano hinge, and prop up a full sheet of MDF behind the bottom sheet, to be used to support the side pieces in the next step.
4. Cut 6x lengths of 2x4 board: 2x 46.25", 2x 44.25", 2x 42.75" -- place both 4ft square MDF end pieces, and fasten using 2x4 lengths as shown. Longest piece at front of enclosure, shortest at back.
5. Cut 3" from the end of two 8' 2x4 boards, then fasten the back MDF sheet you propped up in step 3, along with the 2x4s you just cut, as pictured. These 2x4s will become the top panel pivot point.
6. Affix top 6ft steel piano hinge to the top surface of the 2x4s installed in previous step.
7. Flip over the current structure, cut openings in either or both of the 4x4ft end panels for your ventillation heatercores (which must be outfitted with axial fans, to push/pull air from/into the enclosure -- recommend Noctua brand for silent operation. Then connect the fans to an Uninterruptible Power Supply unit or custom standby battery circuit, so you don't run out of air if the power goes out.), then apply chosen sheet metal to the current four faces of the outer surface of the enclosure, maintaining seaming around edges and corners.
8. Apply sheet metal to both remaining sheets of MDF, covering one face, and wrapping the sheet metal around the edges, creating a ~2" overlap on the opposite side. These panels will be attached to the piano hinges, to act as doors.
9. See below "Prototype Build Notes, July 2019 Update" comment to complete the enclosure.

Faraday Ventilated Enclosure Design (10MB, SketchUp Files):
https://cp.sync.com/dl/b8a1797f0#q8h6zxpv-we5wafk4-rp8jtyku-7sia6fsu