Thanks for the compliments. I'll try to answer some questions.
Overhang - BIG knows this, he had this little wooden contraption he had previously built, AKA the "magic spacer tool" that he used to cut the overhang. I'd guess it is about 1 1/2" from memory, but he can answer that.
Rope Light - The fire effect was fortunately just how the rope light turned out. I picked up a spool of 5/8" ultra bright red rope light from 1000 bulbs. I literally just wrapped it around the room and nailed it to the wall with little round clips. It's not absolutely pulled tight straight, because the clips can't hold that tension, so it sort of wavers a bit up and down (hence why the lighting isn't uniform). Height wise, it is against the wall right where our little light-box blockers ended vertically. I just used those as my height spacers. The flat black paint sort of soaks up the light so it bleeds away. The nicest effect is how it lines the bottom of the trim along the top with a bright red line. It's very distinct when entering the room.
Soffit Fabric. Oddly enough, wrapping the soffit panels was much harder than the speaker frames. Mostly due to the round edges of the pipes. There was a lot more places for the fabric to catch on the plywood. We just used 8' long 3/4" plywood for the soffit panels. On the sections that covered the HVAC ducts, we made it a solid plywood board. On the other sections, we cut out the center. You may wonder why we bothered to do this, since it ends up just a frame. Seems like a lot of waste for wood, but in truth, it was easy, almost cost the same, and saved a ton of time. Making frames out of MDF or plywood that would not bend under the tension of the tightened GOM would not be easy. Plywood natrually is very difficult to bend in the direction parallel to its compression pattern (from side to side across the 3/4" thickness) unless it is an extreme length. We had 2 8' panels that were completely open in the middle. We made one completely hollow, and the other two big holes (so there is a middle support). There were two shorter hollow panels that were about 4'6" or so, and that did not need a support. But the 8' panel did, or it would bend.
BIG posted some pictures (Open Smaller Panel)
and (HVAC panel, solid, with a cutout for the HVAC register)
We basically made sure the panel was straight along the fabric and used a fabric stapler on one corner, and then pulled it tight on the same side to the opposite corner and stapled there. Then we would run staples across that entire side. Then we would pull the fabric across the panel and tighten it in the center of the opposite side and staple there. In small sections about 8" long BIG would pull across the width of the panel tight and slightly away from the center staples and we would run a half dozen staples down the other side. We would repeat this in these small sections until getting to the corner. Then we did the same thing to the opposite side of the center. Then we would staple the center of one end, and then pull it tight on the opposite end and staple the center there. Then we would repeat the same things we did on the sides, finally folding over the corners like a gift package.
On panels like the ones with the HVAC register, once the panel was completely wrapped and tight against the surface, we would staple along the edges of the HVAC register cutout to make sure it remained tight after we cut it, and then with a utility knife & shears, we cut across the middle of the hole, and then diagonal towards the 4 corners so that we could wrap the fabric around the inside. We then stapled that fabric on the opposite side of the panel.