Re: Lightweight Theater walls

On May 15, 5:57 pm, WilliamMLov...@[EMAIL PROTECTED]
 wrote:
> I want to build light weight walls for a theatre production at my
> church. I am looking for suggestions for the wall surface (panel)
> material.
>
> Background:
> Here is what I need:
> - The walls must be 12 feet high
> - They must be lightweight
> - They must be easy to setup and teardown and move to storage
> - The walls should not warp while stored.
> - The walls will be decorated will various things like paint, foam etc
> as needed.
>
> Here are my current thoughts:
> - I am thinking of building walls in 12 feet by 4 feet sections. This
> is a manageable size and materials are often sold in 4 by 4 or 8 by 4
> foot sections so 12 by 4 should be easy to construct.
> - I plan to join wall sections together so each section should easily
> attach to neighboring sections.
> - I am thinking of some sort of panel material attached to a frame.
>
> The Frame
> I think I have found satisfactory frame materials. Since wood tends to
> warp, I am thinking of angle aluminum or "slotted" angle steel.
> Slotted steel has many holes predrilled in it so it is quite light and
> can be easily bolted to the neighboring sections.
>
> The Panels
> Here is where I need help. Normal plywood is too heavy. I have seen
> corrogated plastic. This has some value but seems flinsy.
>
> Can anyone suggest other possible panel material and how I can optain
> it?
>
> Thank you

Hello.

My first concern is the idea that you want to use aluminum to make the
frames.  I would highly suggest against this for two reasons.  First,
aluminum would not be cost efficient.  Second, unless you are planning
to bolt together the aluminum pieces, you will need to find someone
who can weld aluminum.  Ultimately, going the route of aluminum would
be very difficult, and I wouldn't suggest it.

My suggestion would be to make a Broadway-style hard-covered flat
(Another person has replied who describes Hollywood vs. Broadway flats
as being hard-covered vs. soft covered (Muslin).  He is not entirely
correct; Broadway vs. Hollywood deals with the frame, not the panel
material).  Create these out of 1x4 and 1/4" Lauan plywood.  First of
all, rip down the 1x4 from 3.5in to 3in (This will save some weight.
You can go down to 2.5in, but I would not suggest it for something of
long term use).  Frame the frame with the 1x4 flat, NOT ON EDGE.  I
would assume that you are going to use corner blocks and keystones to
frame it.  Make sure you leave all corner blocks and keystones 1" away
from the edge of the flat.  This way, if you ever make a 90 degree
corner with two of your flats, they will mesh flush and not have the
blocks and stones in the way.  Use 1/4" Lauan to cover the panel.  Be
sure to have a toggle at the seam where the 8' piece and the 4' piece
meet.  Glue and screw (or staple) the Lauan to the frame.

Do not worry about weight.  One strong person or two middle strength
people can carry one of these.  Depending on the humidity, weather,
and how the flats are stored, warping may or may not occur.  If you
pay special attention to the quality of wood you buy and the
construction of the flats, you should have little or no problems
storing them almost anywhere.