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The Cinemar Home Theater Construction Thread

972K views 3K replies 316 participants last post by  mcascio 
#1 · (Edited)

Electronic House 2013 Gold Award Winner
Best Home Theater $25,000 - $75,000
 
 

AVS Home Theater of the Month
 
 
SEATING
* FRONT ROW: 3 Curved Berkline 45003 Black Leather Motorized Recliners
* BACK ROW: 4 Curved Berkline 45003 Black Leather Motorized Recliners

SPEAKERS
* CENTER: M&K S-5000 THX
* FRONT LEFT/RIGHT: M&K S-5000 THX
* ATMOS TOP FRONT LEFT/RIGHT: M&K SS-150 THX
* ATMOS TOP REAR LEFT/RIGHT: M&K SS-150 THX
* SURROUND LEFT/RIGHT: M&K SS-150 THX
* BACK LEFT/RIGHT: M&K SS-150 THX
* SUB1: M&K MX-350 THX
* SUB2: HSU VTF-15H
* SUB 3 & 4: DIY Flat Pack Builds - Dayton Audio RSS460HO-4 18" Reference HO Subwoofer  4 Cubic Feet each

ROOM DIMENSIONS & MEASUREMENTS
* BEFORE WALLS: 27' Deep x 17'9" Wide (excludes theater foyer entryway)
* FINISHED ROOM AFTER SOUND PROOFING: 25'8" Deep x 16'9.5" Wide
* NOTES: The theater is being constructed in part of our unfinished basement. There is a 23" drop in the basement to allow for stadium seating.
* SHORTEST CEILING HEIGHT BEFORE CONSTRUCTION: 8'10"
* TALLEST CEILING HEIGHT BEFORE CONSTRUCTION in Drop Down area: 10'9"
* Front Row: 8'6" from Front of Seat to screen
* Back Row: 14'7" from Front of Seat to screen
* Projector: 16'2" from Lens to Screen
* Screen: 136" Wide 2.35
VIEWING DISTANCE TO BOTTOM OF SCREEN FROM CENTER FRONT ROW
* SEAT INCLINED: 10' 5 1/2"
* SEAT DECLINED: 11' 2"
 

EQUIPMENT
* RECEIVER: Denon X5200W, OLD: Denon AVR-4520CI (11.2), OLD: Onkyo NX-TR3008 (FOR SALE)
* AMP: Emotiva XPA-5 (Center, Front Left & Right, Side Surround Left & Right)
* AMP: Behringer EP4000 (2 Dayton Subs)
* AMP: (2) Dayton APA100 (Atmos Speakers Top Front & Top Rear inside Soffit)
* BLU-RAY PLAYER: Dune HD Max
* GAMING: PS3, (2) XBOX-360
* POWER CONDITIONER: Belkin PF60
* IMAGE PROCESSING: Darbee Darblet DVP5000
* STORAGE: Cinemar MLD-4000 12 TB Mass Storage Server
* PROJECTOR: Panasonic PT-AE8000U
* SCREEN: 136" Wide 2.35 AT Screen (Seymour AV)
* TABLET/iPAD/PHONE USER INTERFACE: Cinemar's MainLobby / MLServer / DVDLobby
* REMOTE CONTROL: Logitech Harmony 700
* LIGHTING CONTROL: Insteon via MainLobby
* THERMOSTAT CONTROL: Proliphix NT-20E Thermostat via MainLobby
* INTERCOM: Not sure yet - most likely go with Russound
 
CARPETING
* Masland Quadrate Times Square
 
FABRIC
* Red Walls - FR701 GOM Style 2100 (#418) Claret Accent Fabric
* Speaker Frames - FR701 GOM Style 2100 (#408) Black Fabric
* Top of Front Cabinet Below Screen & Sides of Vertical Front Cabinets Facing Screen - Protostar Self-Adhesive Flocked Light Trap Material
* Bordering Edges that the Seymour AV Screen sit's on - Black Triple Plush Velvet

SOUND PROOFING
The room above the theater is a nursery and office. One of the rooms next to the theater is a furnace room. So it's important to keep the sound out of the rooms above and prevent sound coming in from the furnace room.
Current plan of attack is to use two layers of 5/8" drywall and Green Glue with sound absorption clips. Staggered stud walls will be on any framed walls.
* Minimum 1-3/4" Solid Core Door with automatic door bottom.

PAINTED STAR CEILING
* Hand painted black light star ceiling painted by Night Sky Murals
 
VIRTUAL MOVIE POSTER
* A 40" LED TV mounted in Portrait displays the Cover Art of the currently movies along with statistics like: Number of Movies watched in theater, Minutes remaining of playing movies, movies coming soon, lbs of popcorn consumed, etc.  The user interface on the LED Movie Poster is powered by MainLobby.
 
BASS SHAKERS
Aura Pro Bass Shakers in Back Row (4 Chairs)

SOUND TREATMENT
Recycled Denim/ Titus EcoShield (1" x 4' x 50') (Bought from Vyron Corporation)

D-BOX MOTION PLATFORM
D-Box Motion Platform in Front Row (3 Chairs)


VIRTUAL (MATTERPORT) WALK-THROUGH OF CINEMAR HOME THEATER
https://my.matterport.com/show/?m=ur3p2q8Hk9r



UNFINISHED BASEMENT AREA


FINAL ATMOS SPEAKER PLACEMENT






MY ORIGINAL PROPOSED THEATER DESIGN (Top View)


MY ORIGINAL PROPOSED THEATER DESIGN (Side View)


LATEST THEATER DESIGN (Top View)


LATEST THEATER DESIGN (Side View - RESERVED)

LATEST THEATER DESIGN (3D View)







 
 
FABRICS, CARPET & PAINT INFORMATION

 
 
 
COMPOSITED 3D IMAGE WITH ACTUAL PHOTO [There is an angled divider.  The Left Upper Area is the actual photo, the right lower area is 3D]

 
FINAL ACTUAL PHOTO WITH NIGHT SKY MURAL STAR CEILING:

 
LED TV MOVIE POSTER DISPLAYS CURRENTLY PLAYING MOVIE AND ACTUAL START / END TIMES USING CINEMAR'S MAINLOBBY SOFTWARE

 
iPad Movie Selection using Cinemar Software. Also controls thermostat, lighting, projector, receiver and security.

 
THREAD INDEX
* 12.22.09 - Construction Thread Started
* 04.27.10 - Generac House Generator Installed
* 12.04.10 - Cleaned up 4 Miles of Cable in Media Rack
* 03.19.11 - Construction Lumber and Green Glue arrived, Reworked Sump Pump Area and Added Additional Breakers to Media Rack Closet
* 03.25.11 - 3D Renders of Rec Room Area outside Theater
* 03.27.11 - Framing of Interior Basement Walls Started
* 04.03.11 - Theater Framing Started, Foundation Injection Crack Repair Completed
* 04.16.11 - Illustration Showing Theater Construction using Whisper Clips, DC-04 Clips, Drywall and OSB
* 04.16.11 - Illustration Showing Theater Heating/Cooling Supply Sound Proofing
* 04.21.11 - 3D Wireframe Composite of Seats and Columns within Theater Shell
* 05.29.11 - Dead Vent Framed and Plumbing for Bar Sink Moved out of Theater
* 06.01.11 - Started Framing Soffits
* 06.04.11 - 3D Illustration of Clips and Channel Construction
* 06.06.11 - Started Framing Interior Theater Walls
* 06.08.11 - Raising the Sunken Concrete Floor Up
* 06.12.11 - Theater Room Wiring Diagram
* 06.12.11 - Suspended Sound Proofed Vent Muffler Diagram
* 06.15.11 - Started Construction of Vent Mufflers
* 06.19.11 - Ran Wiring for Speakers, Bass Shakers, Cat5 and Subs. Puddy Pads
* 06.23.11 - Can Light Backer Box Construction
* 06.23.11 - Initial Lighting Diagram
* 06.25.11 - Vent Muffler Installed using IB-3 Clips
* 06.26.11 - Corner Clamps, Acoustic Sealant, Network Thermostat Wired, R19 in Ceiling Started
* 06.29.11 - Speaker and Column Placement Diagram and Discussions
* 06.29.11 - Pipe Wrap on Vent Boots, IB-3 Clips on 2nd Vent Muffler, Instulating Vent Muffler
* 07.01.11 - 2nd Vent Muffler Installed into Soffit
* 07.01.11 - TIP: Whisper Clip Inside Corner Placement Diagram
* 07.03.11 - Hung Whisper Clips and Started Installed Hat Channel
* 07.05.11 - Sound Proofed Cold Air Return 1 and all Hat Channels Installed
* 07.07.11 - Sound Proofed Cold Air Return 2 - From the Inside of the Cold Air Return
* 07.11.11 - Tips and Tricks to hanging Whisper Clips and Hat Channels
* 07.13.11 - HVAC Items Completed: Dead Vent Inline Fan Installed and enclosed, Air Tubes installed for Vent Dampers and Arzel Zones
* 07.18.11 - Theater Insulation Nearly Complete, All Holes Caulkded and Puddy Pads on Light Gang Boxes
* 07.18.11 - Theater Foyer Sheet Rocked
* 07.31.11 - 5/8" OSB and Plywood installed on Ceiling
* 08.04.11 - 5/8" OSB Installed on Walls (First Layer)
* 08.06.11 - 5/8" Drywall and Green Glue Installed on Walls and Ceiling (Second Layer)
* 08.09.11 - Taping and Mudding Drywall Begins
* 08.10.11 - Gray Primer Applied to Drywall
* 08.12.11 - Our Newborn Arrives
* 08.13.11 - Cement Floor Cut up to Recess Electrical and Data Outlets for Back Row Seating
* 08.21.11 - Elk Security Panel Cleaned Up
* 08.22.11 - MainLobby User Interface for the Elk Security System
* 09.09.11 - Photos of Basement
* 09.21.11 - Patch Panel Cabinet Framed In and Bar Area Cabinets Installed
* 09.26.11 - 2x4x12's Added to Soffit and Stairway Platform Construction Begins
* 09.28.11 - First Row Riser Construction Started
* 09.28.11 - Granite Bar Top Installed
* 09.28.11 - DBox Alumninum Frame Assembled
* 10.04.11 - First Layer of 3/4" OSB Installed on First Row Platform
* 10.05.11 - Second Layer of 3/4" OSB Installed on First Row Platform
* 10.06.11 - Profile Illustration of Bar Construction Outside Theater
* 10.11.11 - Riser Step Framing Started
* 10.15.11 - Front Stage Framing Started
* 10.19.11 - Second Layer of 3/4" OSB Added to Front Stage and Steps
* 10.20.11 - Composite Image of Actual Photo at Stage of Construction with 3D Wireframe Render
* 10.22.11 - Filled Stage with Sand
* 10.24.11 - Composite Image of Actual Photo at Stage of Construction with 3D Render
* 10.24.11 - Insulated Areas of Front Stage and Side Steps
* 10.25.11 - Cutting OC703 and Corner Bass Traps Installed
* 10.26.11 - Projected Video onto Wall for estimating Appropriate Screen
* 10.26.11 - Nailed Two Layers of Recycled Denim to Screen Wall
* 10.27.11 - 3D Renders of Red Vs Black Soffit Underside
* 11.02.11 - Cut 16 Holes for 4" LED Can Lights
* 11.04.11 - First Coat of Benjamin Moore Starry Night Blue rolled onto Star Ceiling Area
* 11.11.11 - Can Light Housing Installed in Open Soffit
* 11.12.11 - Patch Panel Terminated
* 11.13.11 - Started 3/4" MDF Speaker Column
* 11.18.11 - Column Construnction Plans with Measurements
* 11.18.11 - Moulding Installed on Bar Cabinets
* 11.18.11 - Bar Plan with Measurements
* 11.18.11 - Rec Room Photos
* 11.21.11 - More Column Construction and Moulding
* 11.22.11 - Detailed Diagram of Mouldings and their Profiles used in the Theater
* 11.23.11 - Building a Removable Magnet Speaker Frame with Black GOM Fabric
* 12.12.11 - Spray Painting 4" LED Can Lights Black
* 12.14.11 - Installed 4" LED Can Lights
* 12.17.11 - Completed Removable Speaker Grill Frames
* 12.18.11 - Attaching Columns to the Wall
* 12.19.11 - Installing Gang Boxes for Data and Electric into Columns
* 12.26.11 - Started working on Oak Steps and Bull Nose
* 12.27.11 - Quick Tips on Cutting Curves with the Jig Saw
* 12.27.11 - Carpet VS Hard Wood on Stage Renders and Discussion
* 12.31.11 - Creating the Large Curved Bull Nose in front of the Front Row
* 01.03.12 - Started Cutting the Oak for the top of the Front Stage
* 01.08.12 - Adding 1/2" Base Shoe under Oak Steps and Bull Nose to create Rounded Underside Edge, Assembling the Front Stage Step
* 01.13.12 - Assembling the Top Front Oak Stage
* 01.16.12 - Using a Biscuit Joiner to Assemble the Front Oak Stage
* 01.21.12 - Started Attaching Lower Third 3/4" MDF Panels to Wall using Green Glue and Screws
* 01.22.12 - Finished Mounting all Columns
* 01.26.12 - Photo Comparison of Protostar, Sy Fabrics Black Plush Triple Velvet and Fidelio Velvet
* 01.29.12 - Routered Bull Nose with a 1/2" Round Over Bit on Front and 1/8" Round Over Bit on Back Side
* 02.01.12 - Started Building 45 Degree Front Corner Cabinet Frames
* 02.09.12 - Started Building Front Arched Cabinet Frame
* 02.15.12 - Notching the Divider Facers for the Front Cabinet Frame
* 02.18.12 - Front Center Cabinet Door Construction
* 02.20.12 - Composite Image of Actual Photo at Stage of Construction with 3D Render
* 02.22.12 - Front Corner Cabinet Doors Installed
* 02.23.12 - TIP: Assembling Bowed Boards during Cabinet Door Construction
* 02.27.12 - Added Base Cap Moulding to Cabinet Doors
* 03.04.12 - Magnetic Latches
* 03.11.12 - Creating a Sharped Seam Fabric Soffit
* 03.18.12 - Installed a Recessed Temperature Sensor
* 03.19.12 - Finished Sanding Bare MDF Column Edges down to 220 https://www.avsforum.com/forum/post/1470#post_21797382"
* 03.21.12 - Built Corner Pine Cap
* 03.22.12 - Applied MH Ready Patch to all joints and Screw Holes on Columns 
* 03.25.12 - Finished GG all lower wall MDF, Notched Bullnose for Baseboard, Final Installation of Bullnose Behind Front Row 
* 03.28.12 - Diagram with Dimensions Showing Construction of Bullnose and Stair Tread using Base Shoe 
* 03.31.12 - Diagram with Dimensions Showing Tall Column Construction
* 04.02.12 - Started Installing Crown Moulding around Perimeter of Room
* 04.03.12 - Coped an Inside Corner Crown Moulding
* 04.04.12 - Started Installing Chair Rail
* 04.05.12 - Composite Image of Actual Photo at Stage of Construction with 3D Render
* 04.07.12 - Started Column Trim Moulding, TIPS
* 04.09.12 - Started Installing Base Board
* 04.11.12 - Started Installing Panel Moulding
* 04.17.12 - Started Construction Fabric Panels
* 04.20.12 - Tips on Cutting GOM Fabric [Rotary Cutting Tool, Straigt Edge Clamp]
* 04.23.12 - Building a Fabric Frame around Receptacle Switches and Vents, Started Double Jamb Door Construction
* 04.27.12 - Installing Door Hinges and Door Lock
* 04.30.12 - Hanging Door and Double Jambs
* 05.04.12 - Built Patch Panel Door within a Fabric Frame
* 05.06.12 - Building Fabric Frames Surrounding Door Casing
* 05.07.12 - 3D Concepts of Potential Back Bar
* 05.08.12 - Assembling Moulding Frames for Columns using Framing Jig
* 05.14.12 - Started working on D-Box Platform top Using Two Layers of 3/4" Birch Plywood
* 05.17.12 - Built Recessed Access Panels for D-Box Actuators
* 05.22.12 - Started Installing GOM Fabric Under Soffit Light Tray
* 05.31.12 - Final Light Tray Moulding Diagram, Started Installing Soffit Mouldings
* 06.06.12 - Room Cleanup and then Started Priming the Room
* 06.07.12 - First Coat of Black Benjamin Moore Paint
* 06.17.12 - Installing Shelving Brackets for Speakers, Working on Theater Foyer Moulding, Stapled GOM Fabric to Cabinet Door
* 06.20.12 - Nearly Finished Painting
* 08.13.12 - Construction Completed
* 08.28.12 - LED TV Movie Poster Now Displays Start / End Time of Movie using MainLobby
* Working on Room Acoustics, Picture, Automation User Interface
* 11.05.13 - Dual Sealed DIY 18" Dayton Subwoofer Construction
* 11.05.13 - Dual Sealed DIY 18" Dayton Subwoofer Construction (External Thread)
* 01.13.14 - Aura Pro Bass Shaker install in Berkline Chair
 
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#1,177 ·

Quote:
Originally Posted by phisch /forum/post/21469694


Mario - Nice woodworking job on those stairs and stage. How do you plan to finish them? In your renderings they are black, do plan on using an ebony stain and poly, or are you applying a dye and lacquer?


That's a good question. I hadn't really figured this out yet. As usual, I'm open to suggestions and do's and dont's.
 
#1,178 ·
Just wanted to chime in and say that I admire your woodworking skills. Looks like you will have a great stage, congrats and good luck on your project.
 
#1,180 ·
Mario, admirable work! Just finished going through this thread, and looking forward to the finished results. A question regarding your light tray/soffit. There appears to be a "notch" between the layer of plywood that the lights sit in and the second layer of drywall. Are you planning on doing something with that? are you staining the plywood tray?


I would like to do something similar...essentially extend the soffit 6 inches to put the cans in, but have the extended portion go all the way up the the ceiling. Does that sound feasible and/or make sense?
 
#1,181 ·
Thanks guys for the compliments.


rs691919,


Here's a pic I posted a while back on how the tray was constructed. I didn't need L brackets, but I did use 2x4's (instead of the 2x2 pictured) to help straighten out and unify the plywood.




Initally I was going to sand and paint black. But as of right now, the plan is to put red GOM fabric on it and cut around the cans. Then use base board and crown to decorate it.


I don't see why you couldn't do what you are suggesting. Just make sure everything remains decoupled if you are tackling sound proofing as well.
 
#1,183 ·
I need to set some 3/4" material on the top of the stage (2nd layer) to level it out and meet up with the 3/4" Oak that is showing. Is it a bad idea to use 1" pine that I have laying around? It seems much lighter than if I were to use say MDF or OSB. Keep in mind subs will be on that stage.


I'm thinking Green Glue may be the best way to attach then 2nd layer on the top of the stage along with some screws in the hidden areas. Then I could shoot some finish nails through the Oak on the visible areas.
 
#1,184 ·
Recap from last nights work.



Added 1/2" base shoe to the oak top for the stage.




Finished putting 1/4" oak plywod on fronts of stage. Little tricky given the one large piece with the cutout and three 45 degree angles. I used painters tape along the cut line and cut the oak plywood upside down to prevent fraying the edges. I also notched the front step a 1/4" to snugly fit in the oak plywod. I ended up just liquid nailing it and used some carpenters glue.




Turns out I missed a screw. Didn't realize this until going through these pictures.



Now I just need to assemble the one large piece with the two side wings. I'll probably go with the Kreg Jig again. Then finish adding the base shoe to the side wings.



As of now, I'm leaning towards OSB or MDF on the remaining areas of the stage. MDF might be a little easier to maneuver the subs in/out than the OSB.
 
#1,186 ·

Quote:
Originally Posted by TMcG /forum/post/0


Awesome job. You even put professional finish carpenters to shame!

Thanks so much. It's actually not too much different than building in 3D. It's all about finding the right tool for the job. Granted, there are tons of tricks of the trade. Also, it's a little less risky moving a mouse than a saw blade rotating at 6000 rpm.
 
#1,188 ·

Quote:
Originally Posted by GoCaboNow /forum/post/21489174


Very nice. I love the woodworking and and looking forward to your progress and how you finish the wood.

Thanks GoCaboNow.


Here's a quick update from yesterday.


I'll post more photos later when time permits.


But I finished assembling the top layer of the stage. I ended up using Green Glue and MDF. I broke out the biscuit joiner for the first time. Pretty cool little gadget.




I spent a couple hours just cleaning up the room and vacuuming.


Now I'm ready to start assembling the front wall on top of the stage.
 
#1,189 ·
Here are some more detailed pics of Saturday's work in the theater.


Notched the oak along the wall so it will be easier to put the 3/4" MDF on the lower wall.



Marked the center of the #20 biscuit joints:



Cut biscuit joints:



Dry fitted:



Serving up a dish of green glue. I didn't feel like cleaning out the gun for such a small section:










I used biscuits to join some of the MDF to the OAK.



Cleaned up the theater before starting the next phase.
 
#1,191 ·

Quote:
Originally Posted by mcascio /forum/post/21483947


I'm thinking Green Glue may be the best way to attach then 2nd layer on the top of the stage along with some screws in the hidden areas. Then I could shoot some finish nails through the Oak on the visible areas.

I am pretty sure you already know this mcascio, but just in case someone else reading this isn't aware...


Green Glue isn't a glue, you can't use it to attach two pieces of wood together. It is a sound deadening material; it is placed between two solid pieces of material to help dampen sound transmission. For mcascio's stage, after applying the green glue he attached the wood to the stage with nails. If you look closely you can see the nail holes in the picture from yesterday.
 
#1,193 ·

Quote:
Originally Posted by Moggie /forum/post/0



No it isn't but its darn sticky stuff all the same

I stepped on a spot the other day that was over a week old. Stuck right to my shoe. It reminds me of flubber



But yeah it isn't glue.
 
#1,194 ·

Quote:
Originally Posted by BeerParty /forum/post/0


I am pretty sure you already know this mcascio, but just in case someone else reading this isn't aware...


Green Glue isn't a glue, you can't use it to attach two pieces of wood together. It is a sound deadening material; it is placed between two solid pieces of material to help dampen sound transmission. For mcascio's stage, after applying the green glue he attached the wood to the stage with nails. If you look closely you can see the nail holes in the picture from yesterday.

I guess I don't know how strong it is compared to other "glues". But when I cut through two layers of 3/4" osb with green glue in between that had been sitting for probably a month, the two pieces seemed fused together.


I'm glad you pointed that out though. I'd hate for others to use it inappropriately.


As you mentioned, I'd nailed and screwed the top layer to the bottom.
 
#1,196 ·
Doubtful if it would really be seen unless someone was specifically looking at the finishes . . . but even if you did a supreme sanding and painting job on the pine, the final finish will still look different from the painted MDF of the other columns. Like I said, doubtful it would ever be noticed by any visitor, but I would probably just stick with the same material for the rest of the finish carpentry IMHO.


I can't wait to see those renderings become reality! Keep up the great work!
 
#1,200 ·

Quote:
Originally Posted by mcascio /forum/post/21511773


Anyone see any issues with me using select Pine for building the front corner columns and doors below the screen? It'll be lighter and easier to build than using MDF.

Depending on how your finishing the columns I say yes. I built all 7 of mine out of select pine from Menards. I painted it all black then covered with black GOM and couldnt be happier. It's very easy to work with and a bit lighter than MDF. The select pine at Menards is about the straightest lumber they have next to the red oak, maple, aspen stuff that is much more pricey. If you plan to stain/paint it and that is your final product I would suggest something more along the lines of maple, oak or birch.
 
#1,201 ·

Quote:
Originally Posted by ktm250rider /forum/post/21513237


Poplar may be a better choice if your gonna paint it. You won't have to deal with knots.

Most of the "select" pine (at my Menards store anyway)does not have knots.
 
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