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The Theater Which Mercy Built - Page 6

post #151 of 207
Thread Starter 
Slow progress but finally getting a move on. Clips/channel installed in the ceiling. Insulation going into the walls. Cut the doorway into the existing wall - really makes it feel like a room now.

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Question about the screws that go into the channel. I've seen Big's recommendations to use 1 1/4" screws for the first layer and 2" screws for the second. My builder was wondering why the second layer needs to be 2" long if there is only 1 1/4" worth of drywall/OSB?
post #152 of 207
Quote:
Originally Posted by rs691919 View Post

Slow progress but finally getting a move on. Clips/channel installed in the ceiling. Insulation going into the walls. Cut the doorway into the existing wall - really makes it feel like a room now.
906894ad.jpg
70af9710.jpg
Question about the screws that go into the channel. I've seen Big's recommendations to use 1 1/4" screws for the first layer and 2" screws for the second. My builder was wondering why the second layer needs to be 2" long if there is only 1 1/4" worth of drywall/OSB?

Seems to make sense that the 2nd layer has a longer screw since it needs to travel through the first layer to attach to the hat channel.

What materials and sizes are you going with?
post #153 of 207
Are you not using 3/4" OSB and 5/8" drywall? This is what I used. These add up to 1 3/8". I don't think a 1 5/8" screw gives you enough margin whereas a 2" screw is plenty long enough without being too long and shorting out your decoupling effort by contacting the clip. If you are not using these material thicknesses then you will have to shorten your screw length accordingly.
post #154 of 207
Thread Starter 
I'm using 5/8" OSB and 5/8" drywall...builder was just curious, he thought 2" was overlong, but didn't think it would be a problem.
post #155 of 207
Thread Starter 
Some progress to report...all the batting was put in, and they finished the first layer of OSB on the ceiling early in the week:

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Yesterday, they completed the first OSB layer on the walls (except for the last couple of feet at the bottom) and putting down the acoutic mat on the floor. First pic is of the doorway and the righthand wall of the theater

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Back wall of theater:

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Front wall:

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post #156 of 207
Quote:
Originally Posted by rs691919 View Post

Some progress to report...all the batting was put in, and they finished the first layer of OSB on the ceiling early in the week:
55329967.jpg
cc8d7202.jpg
Yesterday, they completed the first OSB layer on the walls (except for the last couple of feet at the bottom) and putting down the acoutic mat on the floor. First pic is of the doorway and the righthand wall of the theater
9411c01f.jpg
Back wall of theater:
98442314.jpg
Front wall:
4d9bc131.jpg

Darn, you literally just passed me on progress smile.gif

Congrats, it looks awesome!

Did you put a gap between each OSB or lay them on top of each other? I tried putting a gap but a ~75lbs board gets real heavy real quick tongue.gif
post #157 of 207
Thread Starter 
Well, I'm not doing the work myself so it's not really fair to you! They did have a slight gap between boards (sometimes a little more than I would have liked), but they caulked it all up as you can see by the white lines. Drywall and green glue this week, should be interesting to see how they do with the glue.
post #158 of 207
Well, do you have anything that you can report? It looks like it's coming along nicely.
post #159 of 207
Thread Starter 
Drywall should be complete by the end of today, then they'll start work on the soffits. I'm waiting on the riser till the chairs arrive so I can see exactly how much space I need. Hopefully they'll be in next week. I'll have some pics up tonight. Still trying to push for a Sept 1 completion, but it'll be touch and go.
post #160 of 207
Quote:
Originally Posted by rs691919 View Post

Drywall should be complete by the end of today, then they'll start work on the soffits. I'm waiting on the riser till the chairs arrive so I can see exactly how much space I need. Hopefully they'll be in next week. I'll have some pics up tonight. Still trying to push for a Sept 1 completion, but it'll be touch and go.

Send the drywallers over when they're done smile.gif

I'm almost done caulking my seams.
post #161 of 207
Thread Starter 
Ha! I can barely get them to come over here and keep working! Here are pics of the drywall which was completed day before yesterday. They did some taping and mudding and brought in all the lumber for the soffits yesterday, hopefully they will start framing them today.

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post #162 of 207
Hey looking good. I haven't been around lately and missed a lot! I got a question about ur HVAC poking through the ceiling? It's nice and clean and tight. up in the joists r u using flex and then switched to a metal color to poke through or is it medal through the joists and then u will go to flex in the room?

jimi
post #163 of 207
Thread Starter 
Quote:
Originally Posted by jimim View Post

Hey looking good. I haven't been around lately and missed a lot! I got a question about ur HVAC poking through the ceiling? It's nice and clean and tight. up in the joists r u using flex and then switched to a metal color to poke through or is it medal through the joists and then u will go to flex in the room?
jimi

Metal through the joists and then will go flex in the soffits into the room. Have had huge problems with the contractor and essentially fired him on Saturday, so all progress is at a standstill. I think I found a new guy to finish the rest, but not sure when they'll start. bpape came over last night to drop over some supplies, and we changed the HVAC plan a bit. He felt that one supply should be adequate, and that it would be preferable to have one supply in the front and one high return in the back. So the duct that is sticking out in the back, I'm actually going to disconnect from the supply trunk and make it function as the return. He felt that it's important to have a return high up to get rid of the hot air near the projector, and that having supply in the front would create a better flow of air from front to back in the sealed room. Sounds reasonable for a room that's on 20' x 16'.
post #164 of 207
I totally agree with him on that one. That sticks about the contractor! So the flex is all in soffit for a long run I assume. I k ow he really stressed that with me. I hope all works out its looking good! U got a great person right in ur back yard with I'm nearby!
post #165 of 207
Thread Starter 
Yep, it was great to be able to have him come into the room and check it out. Based on what we talked about yesterday, I have a plan brewing in my head and wondering if it makes sense. Bryan thought the best thing would be to have the supply vent facing forward either above or below the screen wall. Pulling it below the screen wall might be tough. Pulling it above would be do-able -- BUT, I would want to make the top of the screen and screen wall part of the soffit so that I could run the flex duct facing forward above the screen. Thus there would be no fabric frame above the screen -- is this a problem? Hmmm, that doesn't seem easy to visualize, I'll try to make a sketchup pic and post it. I guess the ultimate question is: is it ok to have drywall abutting against the top of the screen frame or does it have to be fabric frames?
post #166 of 207
Thread Starter 
Finally, real progress. I obviously had picked a contractor who was over his head and not up to task. I ended up calling a friend of mine who is a carpenter by trade and with whom I've played softball for the last five years (playoffs start tomorrow!). His boss has a small construction company, and also has played ball with us over the years. I had originally hesitated to call them because they were friends and didn't want to get business in the way. Big mistake. They started today and finished framing the entire soffit in one day. His goal is to have the entire room finished within 21 working days. Finally some excitement - but poor iphone pictures.


Front of room, with two tiered soffit. The bottom tier is to curl the flex duct for supply back around and then have the vents forward facing just above the screen wall:

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Better view of the front soffit:

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Back corner of the room:

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post #167 of 207
Thread Starter 
The new guys I hired are working really hard. Super efficient and intelligent and it's really moving along. Riser was completed last Friday:

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Yesterday they started adding a layer of veneered plywood on the bottom face of the soffit. This will be partly covered with a second drywall layer, much the same as Mario's soffit/light tray in the Cinemar thread. However, I will stain the veneered plywood instead of covering with fabric:

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post #168 of 207
Thread Starter 
Been making good progress despite the main builder being knocked out for a week with what we think was West Nile. Columns installed, fabric stretched across back wall in front of 4" OC703, walls and ceiling painted, trim installed and stained. Next week: screen wall and door, install acoustic panels, cut in space for rack across the hall, and build dead vent.

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post #169 of 207
How's this thing coming along?
post #170 of 207
+1
post #171 of 207
Thread Starter 
Sigh, not well. I've avoided the forum for over a month just because I've been so frustrated. In mid September, I went on vacation to Italy for 10 days. The carpet was due to be installed the day after I got back. Well, got an email from the contractor that the local inspector came by at the behest of a neighbor and was wondering where the permit was. Permit? What permit? Well, 6 weeks later inspections are about complete and some holes were knocked into the finished walls for fireblocking (thanks to the original contractor for telling me he did everything to code). Now the current contractor has to patch up the walls, re-do the fabric which had to be taken down, and build the door. Carpet to be installed next Wednesday, low-voltage wiring to be completed the day before Thanksgiving. So hopefully I'll have all Thanksgiving weekend to play around with iRule and get everything set up. We'll see. I've basically had to stop thinking about it, lest I bang my head against a wall in frustration. I love my neighbors.
post #172 of 207
That's not cool. Sorry you had to go through that.
post #173 of 207
Thread Starter 
Thanks! Well ultimately I only have myself to blame. Should have just gotten the permit in the first place. Ah well.
post #174 of 207
Quote:
the local inspector came by at the behest of a neighbor

Seems like there's one in every neighborhood. Someone with too much time on their hands or is angry about SOMETHING and wants to take it out on someone else. Sorry it happened to you.
post #175 of 207
Quote:
Originally Posted by rs691919 View Post

Well, got an email from the contractor that the local inspector came by at the behest of a neighbor and was wondering where the permit was. Permit? What permit?

Well, I had to look up the word "behest" because the context clues weren't quite sticking out there far enough for me. But after I got the definition from my trusty ole iMac, I will second the notion that the recent events suck pretty hard. Looking forward to more updates. Hopefully.
post #176 of 207
Thread Starter 
Well, at least electrical inspection, which was the last major hurdle, passed today. They can re-stretch the fabric at the back and patch up the drywall Monday. Carpet install Wednesday and rack/electronics install on the 21st. Finally.

I will post pics once the walls and fabric are patched up -- the casework and trim really looks awesome actually. Thanks for the support and kind words!
post #177 of 207
Thread Starter 
Got the walls patched up, cleaned the room up, and had carpet installed...finally some pics and I can see the light at the end of the tunnel. Yesterday I assembled the screen on the floor, put the projector on the floor, hooked up the blu-ray player...projected Braveheart onto the screen. There was no sound and the picture was partly distorted because the screen was on an angle, but it was cool nonetheless. My son was enthralled. Contractor will hopefully install the door in the next two days and finish up the electrical work. Low volt guys are coming on Wednesday to wire the rack and install all the electronics. Getting the room calibrated on Friday by Jeff Meier of Accucal. Almost there!!!

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post #178 of 207
Looking incredible. So glad you got over the neighbors hurdle and can see the end ahead. That wood grain come up really well.
post #179 of 207
Thread Starter 
Thanks! Yeah, they did a nice job staining it. Have to thank Mario for the inspiration though!
post #180 of 207
Quote:
Originally Posted by TheSly View Post

Looking incredible. So glad you got over the neighbors hurdle and can see the end ahead. That wood grain come up really well.
+1
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