Iowa Class Battleship FULL-SCALE 16" AP Round

This is a full-scale model of an Iowa class battleship's 16-inch Armor Piercing shell. It is sliced to fit on a 256x256x256mm build plate. There are 26 plates and takes almost 12 KG of filament (at 5% infill) and over 8 days to print. Recommend printing the layers in sequence as each four plates (1-4, 5-8, 9-12, etc.) combine to form a layer except plates 25 and 26, they are single layer pieces. I used 5% infill on all plates except plate 25 (9%) and plate 26 (15%).

For size comparison, added a picture of the shell sitting in a 6' 8" tall door frame.

Build suggestions:

1. Dry fit all pieces before gluing. I used a deburring tool to slightly bevel the outside rim of each peg hole. (Allows for easier peg alignment when assembling).
2. Ensure all support material is off the underside of each horizontal peg (the pieces need to meet flush).
3. In a layer, join 2 pieces first, then join the other 2 pieces. Then join these connected pieces (dry fit each layer first then dry fit on lower layer!!!).
4. Be careful, layers 2 and 3 look alike. I randomly placed pegs so each piece will only fit one way. I marked each layer section on the inside with a sharpie. I also matched up one layer piece with its lower layer position and marked a line on both. Made for quicker alignment when getting ready to mate two layers.
5. I screwed up plates 15 (Layer 4-3) and 16 (Layer4-4) negative pieces on the inside. The inner hollow (negative) area will not look round but the pieces fit together well and cause no outside display issues. (my bad).
6. Use a slow setting glue to allow alignment time (I used 6 tubes of Testors plastic model glue for entire build)
7. I also used straps and clamps to hold each glued layer until glue set. Be careful using clamps on top pegs, I broke one off.
8. Recommend printing next layer and dry fitting together to act as top guides when gluing lower layer pieces together.
9. If you use care, will almost have no gaps. I have some small gaps but will easily fill in and sand.

I printed all plates using the same P1S printer. Used inexpensive white Sunlu PLA+ filament ($10.95@). Had ten automatic AMS mid-print filament changes and all worked flawlessly. The end of the filament pulls clean (and straight) from the roll. Printed all 26 plates without any issue or misprints.

I plan on painting per the attached picture (black, yellow, copper, and brass).  My plan is to admire for a while then donate to my local American Legion. They don't know it yet so mums the word!

Mainly printed just to see if I could do it.