Stages and risers almost complete - Page 4 - AVS Forum
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Dedicated Theater Design & Construction > Stages and risers almost complete
Mark P's Avatar Mark P 06:59 AM 10-15-2005
Quote:
Originally Posted by v1rtu0s1ty View Post

Hi mark,

I really would like to learn how you created those rounded stage. What tool did you use and can you share how you did it please?

And also on your ceiling, I saw a big perfect round hole/circle in the middle that's been drywalled. What did you do so that when drywall is bent while being installed, it doesn't break? It's totally cool!

Thanks! Awesome theater!!!!!!!!!!!!!!!!!!!!

I detailed the stages on the first page I think, Maybe the second?

the " Hole" was coverd in 3/8 plywood first and to sheetrock it you soak the drywall and it becomes more flexable, the plywood makes a ridgid surface to push the wet drywall into. A friend of mine did my sheetrocking for me, this would have takin me weeks, his crew and him were done in a day having it firetaped, they finished it the next day using hot mud
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v1rtu0s1ty's Avatar v1rtu0s1ty 08:18 PM 10-16-2005
I have a question. Please look at the image below: On the blue arrow, how were you able to make a curve/arc on the wood? What tool did you use? How thick is the wood?

On the red line, am I correct that it is a plywood? How thick is it?



Thanks!

Neil
AnthonyP's Avatar AnthonyP 09:02 PM 10-16-2005
v1rtu0s1ty: to me it looks like two pieces a flat one on top and an other on the side.
v1rtu0s1ty's Avatar v1rtu0s1ty 09:18 PM 10-16-2005
yeah, i know they're separate. But how was the cutting done on the wood pointed by the blue arrow?
AnthonyP's Avatar AnthonyP 09:25 PM 10-16-2005
sorry, from your question I though you were asking how he curved the wood.
Toxarch's Avatar Toxarch 11:15 PM 10-16-2005
I would guess he just drew the curve on some wood and cut it with something like a jig saw or maybe a reciprocating saw.

As for the red arrows, you might be able to bend 1/2" plywood like that if it's a real easy curve. I used 2 layers of 1/4" plywood.
v1rtu0s1ty's Avatar v1rtu0s1ty 12:18 AM 10-17-2005
Thanks!
Mark P's Avatar Mark P 12:33 AM 10-17-2005
sorry guys I was at a Hometheater get together up here in Portland tonight, very fun

I used 8 sheets of 3/4 plywood layed on top (4 on top of 4) of each other making a 1-1/2" thick piece of plywood 8' wide by 16' long then I made a "compass" I will call it out of a 1 x 6 pine board that my Plunge router fastened to at one end ( using a 1/4" upspiral bit) and put a screw centered into the other end 8' away , this allows me to cut a perfect arc in several passes as to not burn up the bit , then I moved the screw 3-1/2 inches closer to the router but used the same hole and routed again making what appears to be a long curved 2x4

My method is hard to explain but easy to talk through or show, maybe I will see if any of my old picks show what I am talking about
Mark P's Avatar Mark P 12:36 AM 10-17-2005
Oh sorry I forgot, the fronts are indeed 1/2" plywood with relief cuts every inch about 1/8" deep using a sliding chop saw with a laser line on the blade this takes little time but 1/4" would surely make the bend .
v1rtu0s1ty's Avatar v1rtu0s1ty 12:48 AM 10-17-2005
Hi Mark,

I understand now when you explained how you made the cutting for the arc shape. That's really cool. Hmmm, I've been seeing/hearing the equipment called router. Did a google search and I saw this, http://www.amazon.com/exec/obidos/tg...84021?v=glance

I'm interested on how this looks like, 1/4" upspiral bit. Do you have some screenshot? It's because, I would like to know how the staircase nosing is built. This way, I don't have to buy the nosing at Home Depot. And also, once I have the tool, I can create my own nosing most especially for custom shape stage or riser.
Mark P's Avatar Mark P 01:22 AM 10-17-2005
heres a pic of it going together , the entire process was filmed in HD but I neglected to take pics of the actual routing
Mark P's Avatar Mark P 01:38 AM 10-17-2005
heres an upspiral bit,



available at any Lowes or Home Depot

I use 1/4" x 2-1/2 long , took 2 to build this stage but thats alot of routing and yes that router you provided a link to is a plunge router , I prefer Hitachi s because they give you freebie accessories and they route forever with simple quick changing of bits

Since I am carpeting over the edges of the stages I just used a 1" roundover bit on the top and bottom edge of the "platform"


v1rtu0s1ty's Avatar v1rtu0s1ty 08:47 AM 10-17-2005
Thanks Mark! That really helped me a lot!!!!
Toxarch's Avatar Toxarch 12:39 PM 10-17-2005
Quote:
Originally Posted by Mark P View Post

sorry guys I was at a Hometheater get together up here in Portland tonight, very fun

I used 8 sheets of 3/4 plywood layed on top (4 on top of 4) of each other making a 1-1/2" thick piece of plywood 8' wide by 16' long then I made a "compass" I will call it out of a 1 x 6 pine board that my Plunge router fastened to at one end ( using a 1/4" upspiral bit) and put a screw centered into the other end 8' away , this allows me to cut a perfect arc in several passes as to not burn up the bit , then I moved the screw 3-1/2 inches closer to the router but used the same hole and routed again making what appears to be a long curved 2x4

My method is hard to explain but easy to talk through or show, maybe I will see if any of my old picks show what I am talking about

Mark, I think your work on the stage is very nice but I really think you could have done it much easier. Just build the frame without the sandwiched plywood pieces and without the cutouts in the 2x6s. You can use 2x6s between the curve supports for added strength. Add the plywood for the face of the stage and then add the curved top for the stage. Should be much easier than engineering your own curves 2x4s out of sandwiched plywood and it'd be just as strong.
Mark P's Avatar Mark P 02:23 PM 10-17-2005
you know I thought of that but I have rope lighting running top/bottom around each curve and the only way I could get rid of it ( hide it ) was to route channels for it into the 2 x 4s I made, its hard to explain I could probably take a picture
Mark P's Avatar Mark P 07:14 PM 10-18-2005
Isco 3 anamorphic lens showed up and this baby is a brute, weighing in a 10 lbs. Packaged very nice and is amazing . Took all of about 1/2 hour to be up and running thanks to Alan.



For those that have seen the Mercury HD and know how big it is , this lens just sorta fits right in. ( may have to beef up the balcony)



Putting it through the test in about 15 minutes with Batman Begins
mmmkam's Avatar mmmkam 01:02 AM 10-19-2005
Drooool!
jamis's Avatar jamis 04:50 AM 11-08-2005
Can't wait to see more!
Darkking's Avatar Darkking 05:07 AM 11-08-2005
Yeah! It's been a couple of weeks since last report. Guess the test of Batman Begins was successful and all is happening now is a whole lot of movie watching

Dave
dc_pilgrim's Avatar dc_pilgrim 07:15 AM 11-08-2005
I have been thinking about this thread in the last week or so, wondering how it was going. I had forgotten the name of the thread title. So I am mostly posting to remind me to check this thread more often.

Also, to add kudos on the theater. Thanks for showing off the lens too - its pretty mean looking.
Mark P's Avatar Mark P 08:40 AM 11-08-2005
Sorry guys,
No goodies, since the HTPC got sidetracked all the stuff that had been neglected getting ready for winter.

Once we found out the chairs were going to take 3 months , everything turned to movie watching mode and dealing with automation and loading up the media server .

If the weather turns foul I will work on the balcony .

Several mistakes made in this build

1. Hang screen
2. position projector
3. receive anamorphic lens
4. Install Blackouts
the crane's Avatar the crane 03:16 PM 11-11-2005
You have to be flipping kidding me? That place is nuts!
SR1355's Avatar SR1355 04:39 PM 11-11-2005
I offically have lense envy!!!
heartsurgeon's Avatar heartsurgeon 12:52 PM 11-12-2005
Quote:


I'm working on a PDA as a voice command remote

that's really a neat idea.....

your "wow" factor is going to be over the top....even more.....
Static Wick's Avatar Static Wick 07:25 AM 11-17-2005
Ba Ba Bad to the Bone...
keithmcelhinney's Avatar keithmcelhinney 08:03 AM 11-19-2005
Please stop posting picture of you theater. My heart really can't take it!

I am in process of planning my new theater. My first theater was a definite budget job, but I loved it! I now am trolling the forums for design ideas for my new one which (hopefully) won't be such a budget theater. Now I come across yours and I can't think stop trying to fit in a balcony in my 9' tall basement!

To restate: ABSOLUTELY AMAZING!

-Keith
R_Willis's Avatar R_Willis 08:29 AM 11-19-2005
Love it.

Words can't really describe what you have going on there.

MarkP: you available for hire, if and when I win the super lotto?
klutzo's Avatar klutzo 09:50 PM 12-03-2005
*sigh* I wish I had that space!

Awesome how you guys went into the attic though.. Very novel idea. Our new place has room for me to put in a 10x14' HT, so am planning it now. I don't think the wife would approve if I went up into the kitchen with a balcony seating plan. =>
Mark P's Avatar Mark P 11:29 PM 12-03-2005
Quote:
Originally Posted by R_Willis View Post


MarkP: you available for hire, if and when I win the super lotto?

Are you kidding me, I hope I never see a HT again, and i wouldnt wanna steal all your fun
Mark P's Avatar Mark P 11:31 PM 12-03-2005
Quote:
Originally Posted by klutzo View Post

*sigh* I wish I had that space!

Awesome how you guys went into the attic though.. Very novel idea. Our new place has room for me to put in a 10x14' HT, so am planning it now. I don't think the wife would approve if I went up into the kitchen with a balcony seating plan. =>

Ask her if she'd rather cook or watch movies, she might suprise you with her answer
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