Originally Posted by BIGmouthinDC
COLUMN BUILDING DETAILS
Recalling an earlier post the columns were inspired by Sandman's original round columns. So the question was without buying half round plywood forms like Ruben, what could we do to create some roundness and strong horizontal lines like Ruben's grooves.
Here is the idea Damelon and I came up with:
A three part column with rounded out trim above and below the speaker area. The speaker area will covered with black GOM FR701.
I built a prototype of the round out area to test the look and materials
Damelon said go
First up was a cutting a bunch of wood for the square box parts. Just 4 sided boxes, no internal bracing necessary, all butt joints.
Then we needed to add a rounded bump out so I needed a bunch of round pieces.
I built a jig to do this.
Mounted a jig saw on a scrap piece of Pergo with double sided carpet seam tape.
I calculated that the radius should be 29.75 inches to get the amount of curve over a 18 inch width. So the distance from the blade to the screw pivot point is 29.75.
Then I mounted the Pergo swing arm on a little Jig
It had a shelf to rest the MDF to be cut
And I cut 36 of these guys
The round outs on the columns consist of three of these pieces glued and nailed to the face of the square column faces. Then I covered the three supports with a piece of wall paneling. It is that faux wood paneling they sell at HD cut into 6 inch strips and just used upside down. The backs actually have a nice smooth finish.
Then I added matching pieces on the sides, you can almost see in this picture:
If you look you can see the base of the column that sits on and off the riser. Had to make the base of those columns at three levels to fit.
Next I needed the bump out trim bits. I wanted something about 3/8 x 1 1/4. Of course there wasn't anything on the shelf that size so I cut down 1x2s to size. I used Tuf Board that they sell at HD. I think it is a mixture of PVC and wood dust. An 8 foot length is like a wet noodle, at 18 inches sometimes you have to use and extra finish nail or two to hold it tight until the glue dries.
I also had to round over the edges
did that with a router table
a little bit later I had enough
cut some pieces to the right length and the right miters
glued and screwed to the fronts, used a spacer for the middle trim
added the sides. Then repeat for the 108 trim pieces.
column at the riser front
The middle section was detailed earlier in the thread, http://www.avsforum.com/avs-vb/showt...1#post20949031
I just need to add that we did fill the metal support members with dry sand. Plugged the bottom end with a wad of insulation and sealed the bottom with black silicon seal, let dry, then Damelon poured in about two cups of sand and we topped off the last 1/2 inch with silicon seal.
full size column
column at the back of the theater
Now I need to fill the nail holes, do some wood putty work, sand, seal, sand, prime and paint.