Originally Posted by GPowers
The saw dust comes from cutting all the two inch strips of ply wood and MDF to make the frames. I use both plywood and MDF. The plywood is the bottom layer and MDF is the top layer. The Plywood helps with strength and the MDF makes a nice clean 45 degree angle.
More saw dust comes from using the router to create the 45 degree corners.
See the attached photo
I started using Velcro, but after the first two frames switched to liquid nails and a 2 inch brad in each of the corners. With the nail gun set correctly the brad disappear under the fabric. If it is still visible i dab the top of the brad with a black felt tip pen.
I am very intrigued by your frames and I may want to use this method. I have access to a complete woodworking shop that over the years I have made some fine furniture. I hope you can answer a few (7) questions.
If I were to build the frames I would use a biscuit joiner machine that cuts into the center of the side of on 1/2 frame and into the end of another section of the frame, this creating a grove for the biscuit to be placed and glued. Using a framing jig this would make a very strong frame. I also have at my disposal a 1/2 shank table mounted router to router the outside edge. I have enclosed a drawing, the red oval is the biscuit of which is made of wood. These biscuits would be installed in each corner of all frames.
How did you join the four corners together?
Did you router the inside edges of the frames as well?
I understand why you used plywood for the strength, but did you not have voids in the plywood after using the router?
Linacoustic, is this the same product used to insulate the insides of ductwork?
Can I assume you cut the Linacoustic to fit within the frame and once the frame is mounted this is how the insulation is secured?
What is the Poly Batten used for?
Are the frames attached to a drywall wall or an insulated frame wall?
Sorry for the questions but you have invested many hours in a beautiful theater and you have firsthand knowledge of what you have done. I am in the process of remodeling our home and will be building a theater room.