On Fri, 16 May 2008 12:25:59 +0100, Daniel Ungard
<Daniel.Ungard@[EMAIL PROTECTED]
> wrote:
> 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.
Or use 1/8" ply, & double skin the central 4' of the flat, very stiff ,
you can still clamp them together easily & lighter.
|
