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Camp Toilet — Feasibility Notes (Condensed)
Baseline
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Existing composting toilet works: cheap plastic bin (~$16) for solids, standard toilet seat on top, sawdust/leaf litter.
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Main deficiency: no urine separation → wet solids, smells, frequent emptying, awkward for women.
Objective
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Add a urine-diverting insert under a normal toilet seat.
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Keep everything else crude, cheap, and familiar.
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One new part only.
Design approach
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Standard toilet seat (comfort, ergonomics solved).
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Plastic bin for solids.
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Urine diverted to a jerry can via a formed insert.
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Vent optional but desirable.
Materials
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PETG sheet for the urine-diverting insert (vacuum-formed).
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ABS / HIPS acceptable alternatives.
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Cheap ply for mould (scrounged packing ply is ideal).
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Polyester body filler (“bog”) for fairing.
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Epoxy or polyurethane for sealing mould surface.
Manufacturing method
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Vacuum forming of PETG over a reusable mould.
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Once mould exists, producing multiples is trivial.
Mould construction
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Build mould by stack-laminating CNC-cut slices:
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Generate rib profiles in Fusion 360.
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Cut on flatbed CNC.
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Dowel-align, glue, sand.
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Fair with filler, seal, smooth, wax/PVA.
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Shed-appropriate, repeatable, low cost.
Geometry (critical point)
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Do not invent the urine-diverter shape.
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Copy a proven design:
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Buy/borrow a commercial urine-diverting insert and replicate geometry.
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Or obtain an STL and adapt it.
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Physical prototyping acceptable, but correctness beats originality.
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CAD role
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CAD is only for:
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Cleaning up an existing shape.
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Generating slice profiles for CNC.
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Geometry acquisition is the real work.
Men’s Shed outcome
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One-off effort to make mould.
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Build time ≈ 30 minutes per unit.
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Material cost minimal.
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Mould can be donated to Shed; project scales easily.
Conclusion
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Project is viable and worthwhile if geometry is copied.
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Everything else is straightforward fabrication.
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