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post #31 of 81 Old 02-11-2009, 03:49 PM
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I like your trimwork and color choice!

What are you planning on putting between the shadowboxing?
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post #32 of 81 Old 02-11-2009, 05:52 PM - Thread Starter
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Quote:
Originally Posted by Ted White View Post

Mark, you have a pic of this boot?

Ted, per request...

It fits inside the extension I previously made with sheet metal. It's securely attached to the wall duct work, but no longer attached to the stage at all. I plan to use linacoustic to line the inside of the small portion of the stage that routes this air to the front. Any issues?

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post #33 of 81 Old 02-11-2009, 05:56 PM - Thread Starter
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Quote:
Originally Posted by koach View Post

I like your trimwork and color choice!

What are you planning on putting between the shadowboxing?

Well, imitation is the sincerest form of flattery! I would thank "Hed" too if I noticed him posting around. Thank again for the advice on the shadowbox. For the inside of the upper boxes, I'm using color matched paint to match the "chino" color of Fabricmate's Audiofine fabric. It can be found here:
http://www.fabricmate.com/audiofine.php

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post #34 of 81 Old 02-12-2009, 09:34 PM - Thread Starter
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Ted, (or anyone!)
Since you asked, any issues with the HVAC route in the pic? I plan to seal around it with HVAC-specific mastic/caulk and put the plywood down on the stage Saturday morning. It will be the only area under the stage floor that is not filled with sand.

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post #35 of 81 Old 02-13-2009, 06:05 AM
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That looks fine, but I'm not sure how the void in the stage would behave.

Like anything we have to merge the technical with the practical

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post #36 of 81 Old 02-13-2009, 06:52 AM - Thread Starter
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Quote:
Originally Posted by Ted White View Post

That looks fine, but I'm not sure how the void in the stage would behave.

Like anything we have to merge the technical with the practical

Yes - it's a small void. If I am really ambitious, I'll go buy some 6" flex duct and add it to the mix! I think I have become a bit tainted by all the perfectionists (nothing wrong with that!) on the forums...

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post #37 of 81 Old 02-13-2009, 04:11 PM
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I'm pretty sure you used the wrong duct tape on the ducts. You should be using the metallic version. What you have in the picture will dry and crack with age and assuming it is tucked away be beyond your reach to fix.

Just a note, a cruel DIY irony is that duct tape is not for ducts,

Lifted this from somewhere:

DUCT TAPE - GOOD FOR MANY THINGS, BUT NOT FOR DUCTS
Duct tape (fabric-based tape with rubber adhesive) is good for many things. People use it as a bandage, to tape up broken plates, to repair their cars. There are thousands of uses. Some folks have even have websites and written books about duct tape. Apollo 13 astronauts used it to repair some equipment to get home to Earth safely from around the moon.

BUT YOU SHOULD NOT USE DUCT TAPE TO SEAL DUCTS!

During World War II, before it was called duct tape, the U.S. military bought quantities of the cloth-backed, rubber-adhesive tape for making emergency repairs on the battlefield. In the movie business it's called "gaffer's tape," used for everything from bundling cables to holding sets together.

Some time after WWII, heating and air conditioner contractors begin to use the tape to seal the joints in heating, ventilation, and air conditioning (HVAC) ducts. This tape was manufactured in the same way, though to match the ducting it was colored silver rather than the green of the Army version. Because of this use, it became known informally as 'duct tape'.

The problem...duct tape does not adequately seal the joints and has a short lifespan.

Over a three-month period in 1998, Lawrence Berkeley National Laboratory (LBNL) researchers tested duct tape and 31 other sealants under accelerated laboratory conditions that mimicked long-term use in the home. They heated air to nearly 170 degrees and chilled it to below 55 degrees before blasting it through ducts. They baked ductwork at temperatures up to 187 degrees to simulate the oven-like conditions of a closed attic under a hot summer sun.

Of all the things they tested, only duct tape failed - and they reported it failed reliably and often quite catastrophically.

Instead of using duct tape, the researchers recommended sealing ducts with mastics, gooey sealants that are painted on and allowed to harden. Metal ducts should be held together with sheet metal screws; flexible duct connections should be secured with metal or plastic bands.

Beginning October 1, 2005, Title 24 of California's Building Energy Efficiency Standards requires that ducts be tested for leaks when a central air conditioner or furnace is installed or replaced. Ducts that leak 15 percent or more must be repaired. More information can be found at: www.energy.ca.gov/title24/changeout/
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post #38 of 81 Old 02-13-2009, 05:51 PM - Thread Starter
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Quote:
Originally Posted by BIGmouthinDC View Post

I'm pretty sure you used the wrong duct tape on the ducts. You should be using the metallic version.

Thanks Big. I agree with your advice! What the pics don't show is a ridiculously tight double/triple layer of the good stuff...shiny, foil faced tape - under the layer you pointed out. I guess I just went overkill with the other stuff. Maybe I'll just put even one more layer of the foil over that! The foil tape is incredible - I used it in a prior house and had to adjust something almost three years later - no curling/failure/etc. anywhere.

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post #39 of 81 Old 02-13-2009, 05:54 PM - Thread Starter
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Big,
One more thing I failed to mention...the whole thing has a very solid coating of mastic over it now too. Yes, I know, ridiculous overkill, but once that stage is covered, carpeted, and there's a screen wall on it, I don't ever want to think about the duct.

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post #40 of 81 Old 02-15-2009, 04:22 PM - Thread Starter
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Big,
Here's the final I was talking about...also, I added a 90 degree elbow as I thought that would help direct the air flow a bit more efficiently to the front of the stage where it exits.

Additionally, I "cemented" (with the mastic) a foam backer rod strip on top so that when the stage floor goes down, it'll be air tight (with a bit of caulk of course).

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post #41 of 81 Old 02-15-2009, 04:25 PM - Thread Starter
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The good news is, the sconces and eyeball trim (for the cans in front of the screen) are in now.



The BAD news is, I took most of the day off Friday waiting for the electrical inspector to show up, and he called my electrician the latter half of the day and indicated he was not going to make it. Doh!!!
On a positive note, my electrician is going to meet him at the house this week, so we should (fingers crossed) pass the final this week.

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post #42 of 81 Old 02-15-2009, 05:32 PM
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Good luck with the inspection.

Great build and great Pics

Must love home theaters!!
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post #43 of 81 Old 02-15-2009, 05:37 PM - Thread Starter
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Thanks Bdoyle,
I am getting close to it all being useable...ordered the carpet this weekend too.

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post #44 of 81 Old 02-16-2009, 06:56 PM
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Mark..... your build is coming together just awesome... a true inspiration... keeps me going.

Sean
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post #45 of 81 Old 02-16-2009, 07:54 PM
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guys...everyone says..they took ideas from HED & KOACH..I dont know how to search and find that thread..can anyone please pm me that link and post it here..

please

My First DIY Screen 120" Laminate Screen

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post #46 of 81 Old 02-16-2009, 08:45 PM
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post #47 of 81 Old 02-19-2009, 02:51 AM - Thread Starter
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Quote:
Originally Posted by sathyakamaraj View Post

guys...everyone says..they took ideas from HED & KOACH..I dont know how to search and find that thread..can anyone please pm me that link and post it here..

please

I've been a bit offline, and will try to post a link this weekend. If you want to see this quickly, scroll up to koach's post, click on the name portion of the post, and view other posts by koach. You'll find his build and I believe there's a photo in it of Hed's theater too.

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post #48 of 81 Old 02-19-2009, 03:49 PM
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Quote:
Originally Posted by sathyakamaraj View Post

guys...everyone says..they took ideas from HED & KOACH..I dont know how to search and find that thread..can anyone please pm me that link and post it here..

please

The link to my build thread is in my signature below. There's some of Hed's pics too.
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post #49 of 81 Old 02-22-2009, 06:46 PM - Thread Starter
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A few updates...
First, finished filling the stage framing with sand and insulation.

The stage decking went in today:

Finally, the screen wall is ALMOST finished - we ran out of 2X4's and another trip to the big box store was not in the plan today! NOTE - that wildly crooked 2X4 in the middle is just there as added insurance until the construction adhesive sets up on the top plate. The adhesive is probably not even needed due to the 2X4's on the sides, but it does offer some stability against the construct moving forward or backward.

The opening on the left will house my rack of gear. The plan is to put it all behind a couple layers of GOM on a velcro panel. I'll be using an IR receiver/repeater of course. I'm going to DIY the AT screen - I've built everything for up to 100" wide, which would allow just over a "standard" 104" diagonal scope aspect screen.
Also, today I finally ordered my projector. However, it will not be going up for a couple weeks as I truly do not want to get distracted! We'll see if I can resist the temptation!
Carpet is scheduled for Monday, March 2, so I have some things to finish next weekend.

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post #50 of 81 Old 02-23-2009, 03:51 PM - Thread Starter
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PASSED the final electric inspection today!
That's all...

Mark
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post #51 of 81 Old 02-28-2009, 07:16 PM - Thread Starter
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I returned home today to find this

Pioneer PRO-FPJ1 - aka, the RS2 clone.

Yes, the lens on my camera is DIRTY...

Anyway, I hooked it up for about 15 minutes just to check it out using a bed sheet as a screen. Very nice...it's funny how much better the picture quality is over my old Sony 400Q. I am excited to see it with HD content.

I exercised some willpower, and it is no longer in the room. It will remain isolated from all temptation until it's time to hang it!
I have a large punch list to tackle tomorrow and some general clean up before the carpet installers show up Monday. I also learned that my Berklines are en route, and I'll have a delivery date by Monday. Aside from knocking out a bunch of small tasks tomorrow, I have a ton of stuff to order: PS3, new receiver, screen material, screen wall fabric, etc, etc! Getting close to having the room useable.

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post #52 of 81 Old 02-28-2009, 09:59 PM
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Wow it's really coming along. Looks great! I like the black walls and black trim.

I wish I did the soundproofing detail you did. And yes hide the projector otherwise in six months you'll still be watching blu rays on a bedsheet

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post #53 of 81 Old 03-01-2009, 07:19 AM - Thread Starter
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Thanks Shawn. I can't take credit for the "look", as Hed and Koach provided me a great template for that. I just boxed up the projector - hopefully it will be ready to come out in a couple weeks!

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post #54 of 81 Old 03-02-2009, 07:06 PM - Thread Starter
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Major progress!
We finished the screen wall and painted it over the weekend. My wife joked that she can at least claim assistance on one item in this build (the screen wall framing paint)! To be fair, she's helped a lot by dealing with the kids while I toil away on this project many times.
Here's the all cleaned up, before carpet pics. One thing this build has revealed is my need for a better camera:



After carpet (lousy quality pics):


Isn't it funny how when many of us grew up, they called it "shag" but now it's referred to by a much "cooler" term, "frieze"?
And, the biggest pleasant surprise today, especially from a timing perspective with me home for the carpet guys anyway, was the arrival of the Berklines! Eight 13175's in black leather - they are so sweet! Again, the picture quality here is a bit lousy, so hopefully I'll have some better ones later.


My wife and the guy helping me out were always a bit nervous about the four chairs across - now that the seats are in, they are completely on board and I am SO glad I did eight seats instead of six. My build was under 14 feet to start, and of course I lost a few inches due to RSIC and DD. The result though is great, with plenty of room for an aisle down the side.

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post #55 of 81 Old 03-09-2009, 05:57 PM - Thread Starter
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Lots of paint progress over the weekend on the shadow box trim. I love the look of it, but when it comes to painting it's a heck of a lot of cutting in X2. The room looks a lot better with some color.

I'm ordering the screen wall fabric and screen material this week...DIY scope screen. I plan to just manually zoom for now until I can add a lens someday.
Enough posting...things to do in the build.

Mark
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post #56 of 81 Old 03-10-2009, 09:39 AM
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Mark,

I do like your wall sconces, what brand & model are they ?

Beautiful theater !

What is your plan to block the light from the tall windows behind your AT screen (excuse me if you have already explained this) ?

John
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post #57 of 81 Old 03-10-2009, 11:46 AM - Thread Starter
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Thanks. Not sure what the brand on the sconces was as I've thrown out the boxes. I purchased them at Lowes - it' one of the brands they stock several kinds of lights in. They were very inexpensive.
Regarding the windows, they will be covered by 1)horizontal blinds, just so they look good from outside, 2) blackout cloth, and 3)I have not decided yet whether I'll cover them with OC703 when I do the wall next week - I probably will.

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post #58 of 81 Old 03-14-2009, 08:10 PM
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Thanks Mark !
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post #59 of 81 Old 03-17-2009, 07:56 PM - Thread Starter
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It's spring break week and I'm taking some time off to do a ton of things around the house...including trying to finish the build!
I spent the last couple days painting...LOTS of touch up work on the trim, can light trim packs, a second coat of the accent color, my screen frame, and the lumber for my fabric frames.
I was pleased to find poplar 1X2's at the local big box store...saved me a lot of time versus ripping 1X4's as I plan to build frames for the screen wall fabric and use velcro to attach.
Boring lumber pic with the simple screen build instructions from Seymour AV's site:

My black Dazian Janus showed up today - I plan to start on the fabric frames tomorrow. I was VERY pleased with the customer service from Dazian. Very friendly, good follow up, and reasonable shipping. Plus, it was packaged exceptionally well.

Anyway, back to the lumber...my screen is going to be approx 97" wide with a 2.37 aspect ratio. First, I measured all the pieces (adding the 3.5" width of the 1X4's of course) and mitered all the corners.

I primed and painted them while I was doing the same to the 1X2's for the fabric frames. I figured that it would be a good way to seal the poplar and prevent any shrinkage/expansion issues given the humidity swings we get in the mid-south.
Here's the screen frame pieces laid out (on the carpet my kids and I absolutely trashed today...it's history in a couple weeks anyway).

Next step was to cut the velvet. Speaking of velvet, I've never felt more out of place and inept as when I went into a "Jo-Ann Fabrics" for the first time in my life over the weekend to buy velvet and black out cloth. I had no clue...good thing they were helpful.

Next, I used the kreg jig to create alternating pocket screw holes. You can see what I mean in the second pic here showing the mitered corners matching up.


Now, it's just a matter of stapling the velvet to each piece.

I finished two pieces tonight...I'm wondering whether the velvet on the ends will twist when I fire screws into the pocket holes. If anyone has suggestions or knows, let me know...I can always cut it back.

I posted a question on this over in the DIY screen section...hopefully someone else has either done this with no issue, or unfortunately ran into fabric twisting issues.

Finally, I ordered a ton of gear over the weekend. The PS3 and Denon AVR-2309CI are on their way, as well as some other goodies. I have some horrible customer service experiences to share...waiting to see if a couple vendors make things right before I jump to criticizing them publicly though.

Mark
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post #60 of 81 Old 03-19-2009, 08:14 PM - Thread Starter
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First - Dave, aka DC Pilgrim - THANK YOU for recommending the Dazian Janus. I started building panels for my screen wall today, and I am extremely pleased with how this fabric looks versus many other samples I looked at.
Today, it was all about the kreg jig, cutting fabric, and discovering why Arrow T50 staples come in standard boxes of 1250 pieces. You think to yourself, "1250...wow, that's a lot and I'll never burn through a box." Well, I'm putting a dent in them for sure.
Step one was to build a bunch of custom frames like this one, to surround the screen, etc.

Quick close-up of the kreg jig joints. I mentioned this in another post, but I love how great the kreg jig works.

Next step, cut the black Dazian Janus fabric, and start stapling (a lot). I started at the center of each panel and alternated sides as I kept the material tight.

The resulting panel (or tribute to 2001: A Space Odyssey)

I did not finish all of them today/tonight, but after just dry fitting (going to add velcro later) a few of them to the screen wall, I am really psyched about how good this is going to look once complete with the screen fabric in place. A couple poor quality pics:


The windows will get covered up tomorrow.
Next steps:
1) finish the screen wall panels
2) build the rack shelves (the Denon showed up today!)
3) Attach the AT screen fabric
and more of course...March Madness is going to get in the way a bit over the next few days!

Mark
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