Making The Brickwork Inside The Tunnel

After ordering a cat tunnel that was advertised to be the size I needed and it turning up to be an incorrect measurement advertised. I decided to push myself to make the corners work with using the rings I had previously made.

To try and simplify my build I decided to reduce the amount of support rings that I had originally used. To do this I remeasured my ground plans to allow me to map out and calculate where I am going to replace my stands.

Using my new measurements I was able to map and place my new set positions for the rings, once I was happy with the position I used hand tools to screw them to the table. I also drilled a hole in the top section of the rings on both sides, I took a piece of wire and threaded it through the holes. This allowed extra strength to hold the structure together.

I used PVC sheets to cut out the sections to make the tunnel. I found the best way to do this was to place the a strip of PVC inside of the tunnel and to draw around the edge of the support rings. This allowed me an idea of where to cut the PVC. Once I had cut all of my sections out I used Gorilla tape top hold the sections in place. I then used contact adhesive and hot glue to attach the wood and the PVC.

I began placing the foam inside the tunnel using strips of the foam, I found they don't perfectly meet up, however by using spare bricks I have been able to fill the gaps. On the sharper inner corners have placed thin strips of polystyrene to smooth out the surface of the bricks.

I have nearly completed one end of the foam bricks, my next step with this section is to cover the foam in foam coat, which will fill any gaps, also making any light less likely to penetrate it. This will also allow me to begin painting.