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Making the "Bacon Race" Theater - Page 8

post #211 of 1892
9/13/11 at 6:56am
Thread Starter 
Quote:
Originally Posted by Brad Horstkotte View Post

Looking good damelon and Big.

I was initially concerned about the heat from those halogen cans, but am happy to report that it hasn't been an issue at all in my place (perhaps because they don't stay on for long).

When I had originally thought out how the light tray might be designed, I was worried about it too, but given that the lights are small and the top of the light tray is open, I'm not worried about heat at all. Since it is not enclosed it doesn't even need insulation.

I have boxes arriving daily. Outlets, dimmers, wall plates, equipment rack, equipment rack door, rope lights, cotton, 703, HVAC grilles, etc. I have to carry a box or two downstairs every time I come home.

At this point I think the only things I don't have ordered are the doors to the room, the projector, and the screen. The only things I need to still purchase outside of all of that is the wood to make the fabric panels.
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post #212 of 1892
9/13/11 at 8:13am
Prototype Speaker grill cover.

Damelon and I have been kicking around ideas on how to build a 46 inch tall 18 x 10 speaker grill cover that would provide the minimum speaker interference possible.

Using perforated metal was one idea that we considered but didn't pursue. Putting a 2x2 at the front edge is a pretty big obstacle. So what about some 1/2 inch iron pipe?

Here is the prototype:







Anyone have any other suggestions?
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post #213 of 1892
9/13/11 at 8:16am
Thread Starter 
Brilliant! Just like I pictured your idea. I agree, this is much simpler and more elegant than the metal grille. Wouldn't a 1/2" wooden dowel rod be easier and cheaper?
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post #214 of 1892
9/13/11 at 8:23am
Another good idea of Big's that I'm going to shamelessly copy.
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post #215 of 1892
9/13/11 at 8:33am
Quote:
Originally Posted by damelon View Post

Wouldn't a 1/2" wooden dowel rod be easier and cheaper?

We would need at least 1 inch dowels for the strength to resist bending when the fabric is pulled tight. They were out of 1's but had a dozen 1 1/4's in stock. Half of them were warped. The others may warp in the future.

On cost, the wood was going to run $4ish a stick, these were $5.81 each. Bottom line they are smaller, stronger and straighter. It is going to cost you $21.60 more to do all 6 columns.
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post #216 of 1892
9/13/11 at 8:39am
When I first built my columns (shortly after the Civil War, I believe), I ripped 3/4" ply to give the lateral strencth needed to not bend. I agree with Big in that a 1/2" dowel would curl like a bow.
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post #217 of 1892
9/13/11 at 8:43am
Thread Starter 
Ted! Nice to see you! Yeah I wasn't sure how well they would hold up. I was trying to think how think my dowel rods are that are in my closets. I'm not good with spacial memory. We already agreed to go with the iron rods and fill them with sand.
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post #218 of 1892
9/13/11 at 9:08am
Instead of iron pipe, how about either metal conduit or chain link fence top rail. Both are galvanized (cleaner than black pipe). Chain link rail is pretty darn stiff too.

Great look, BTW. Yet another idea I may "borrow"
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post #219 of 1892
9/13/11 at 9:21am
Quote:
Originally Posted by petew View Post

Both are galvanized (cleaner than black pipe).

Actually either one has to be cleaned, primed and painted black.

I'll take a look in the fence section but I don't think they have anything this diameter. The 1/2 inch black pipe is 7/8 on the outside.
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post #220 of 1892
9/13/11 at 9:30am
Using pipes for the front vertical members seems like a terrific idea. The round profile should minimize diffraction. Very innovative!
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post #221 of 1892
9/13/11 at 11:46am
Quote:
Originally Posted by petew View Post

Instead of iron pipe, how about either metal conduit or chain link fence top rail. Both are galvanized (cleaner than black pipe). Chain link rail is pretty darn stiff too.

OK, back from the big orange where I had 10 more 44 3/8 long pieces of black pipe cut.

I did some more looking around and conduit had too much give for my taste.
Galvanized pipe in an equal diameter ran $.50 more a foot.
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post #222 of 1892
9/13/11 at 11:57am
Thread Starter 
Quote:
Originally Posted by BIGmouthinDC View Post

OK, back from the big orange where I had 10 more 44 3/8 long pieces of black pipe cut.

I did some more looking around and conduit had too much give for my taste.
Galvanized pipe in an equal diameter ran $.50 more a foot.

I'm jealous BIG. I'm here stuck at work all day when you are having all of the fun. Building movie room is so much more fun than my desk job :P
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post #223 of 1892
9/13/11 at 12:03pm
But I bet you have health insurance. I pay through the nose.
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post #224 of 1892
9/13/11 at 12:17pm
Thread Starter 
Quote:
Originally Posted by BIGmouthinDC View Post

But I bet you have health insurance. I pay through the nose.

Of course I do.... I'm Batman.
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post #225 of 1892
9/13/11 at 12:47pm
Quote:
Originally Posted by BIGmouthinDC View Post

OK, back from the big orange where I had 10 more 44 3/8 long pieces of black pipe cut.

I did some more looking around and conduit had too much give for my taste.
Galvanized pipe in an equal diameter ran $.50 more a foot.

Any risk of the pipe buzzing or rattling or humming or echoing or making any other noise from the speakers/subs?

Aside from that, sounds like a great idea, looks like it will look awesome, I may just have to "borrow" that idea as well...
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post #226 of 1892
9/13/11 at 1:21pm
Thread Starter 
Quote:
Originally Posted by sgolko View Post

Any risk of the pipe buzzing or rattling or humming or echoing or making any other noise from the speakers/subs?

Aside from that, sounds like a great idea, looks like it will look awesome, I may just have to "borrow" that idea as well...

There might be, but that is why we will fill them with sand. My knee-jerk reaction was the same.
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post #227 of 1892
9/13/11 at 1:45pm
Quote:
Originally Posted by damelon View Post

There might be, but that is why we will fill them with sand. My knee-jerk reaction was the same.

Sand is a great idea. Should do the trick.
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post #228 of 1892
9/13/11 at 3:05pm
Quote:
Originally Posted by damelon View Post

....fill them with sand......

Don't let Big Sis see you pouring something into scary looking pipes.

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post #229 of 1892
9/13/11 at 5:41pm
Thread Starter 
That picture is haunting me. I beg of you to remove it for my sanity!
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post #230 of 1892
9/13/11 at 5:56pm
Please nobody use the B word in conjunction with filling the pipes or this thread will get flagged in some government office.
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post #231 of 1892
9/13/11 at 5:58pm
Thread Starter 
Quote:
Originally Posted by BIGmouthinDC View Post

Please nobody use the B word in conjunction with filling the pipes or this thread will get flagged in some government office.

YES. From now on we will refer to them as metal supports. Thank you, come again.
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post #232 of 1892
9/13/11 at 7:50pm
.....
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post #233 of 1892
9/13/11 at 8:19pm
Huh? Is that kind of like not saying:

Hi Jack!

at the airport?
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post #234 of 1892
9/14/11 at 9:44am
SPEAKER GRILL COVERS - PRODUCTION

Last night and this AM whipped up the covers.

First step was to cut the 96 pieces of MDF to length.

Then I made a little jib to make quick work of drilling out the corners for the metal support members, I did the prototype free hand, having a jig made it go faster.







Next was to glue and nail the two layers of frame tops and bottoms. Used a square to keep it square.









Almost done




Remaining steps: paint the metal support members, cut the back uprights, round over corners, assemble at Damelon's, Paint the wood and attach fabric.
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post #235 of 1892
9/14/11 at 10:14am
Easy Peasy
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post #236 of 1892
9/14/11 at 10:26am
That's some drillpress! Looks like something out of 20,000 Leagues Under the Sea. The old version. From Disney.

Great design, as always.
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post #237 of 1892
9/14/11 at 11:30am
Actually it is a 60+ year old Delta that my father had in his shop. Original motor.

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post #238 of 1892
9/14/11 at 6:04pm
Gotta love that old cast iron stuff. Can't beat it.

I have an old Craftsman full size drill press from the late 60s.
From my father's workshop as well. It took three guys to move it, and they finally put it on a dolly.
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post #239 of 1892
9/14/11 at 8:08pm
Awesome work guys. BIG, do you want to come to Auburn and help me with my room?
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post #240 of 1892
9/15/11 at 4:35am
Is your wife a good cook? I do like to travel. It is a 12 hour drive if I have to bring my own tools.
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