May:
the bands on the inside can be made from lexan plastic, and the padding can be either very thin foam, or just cotton batting (we used cotton - cheaper and easier to work with). Although the original balls use a plastic connector to connect the bands when you fold them, we have used two holes (drilled in the end at a diagonal from each other) so that if you overlap the ring ends you can put a pop-rivet through the holes and attach. There are several good step-by-step construction instructions on Chief Delphi, or feel free to contact Team 1511 at
www.penfieldrobotics.com for help with construction tips. Since we're making over 100 of them to host a local competition we've been getting pretty good at it
Cheers,
__________________
Lee Drake, CEO, OS-Cubed, Inc.
Business Mentor - team 1511
Rochester, NY
Building optimal, stable, secure solutions to your business challenges.