On May 16, 7:51=A0am, "Duncan Wood" <bodged...@[EMAIL PROTECTED]
> wrote:
> On Fri, 16 May 2008 12:25:59 +0100, Daniel Ungard =A0
>
>
>
>
>
> <Daniel.Ung...@[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. =A0I would highly suggest against this for two reasons.
=A0First=
,
> > aluminum would not be cost efficient. =A0Second, unless you are
planning=
> > to bolt together the aluminum pieces, you will need to find someone
> > who can weld aluminum. =A0Ultimately, 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). =A0He is not entirely
> > correct; Broadway vs. Hollywood deals with the frame, not the panel
> > material). =A0Create these out of 1x4 and 1/4" Lauan plywood. =A0First
o=
f
> > 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). =A0Frame the frame with the 1x4 flat, NOT ON EDGE.
=A0I
> > would assume that you are going to use corner blocks and keystones to
> > frame it. =A0Make sure you leave all corner blocks and keystones 1"
away=
> > from the edge of the flat. =A0This 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. =A0Use 1/4" Lauan to cover the panel.
=A0B=
e
> > sure to have a toggle at the seam where the 8' piece and the 4' piece
> > meet. =A0Glue and screw (or staple) the Lauan to the frame.
>
> > Do not worry about weight. =A0One strong person or two middle strength
> > people can carry one of these. =A0Depending on the humidity, weather,
> > and how the flats are stored, warping may or may not occur. =A0If 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 ,
=
=A0
> you can still clamp them together easily & lighter.- Hide quoted text -
>
> - Show quoted text -
All these posts are very helpful.
I did not know about 1/8 plywood Thanks for the tip.
Question: what do you mean by "double skin"
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