Well guys, here is an update on my progress. Columns are coming along. I have (6) of the (8) built. Yldesyde/David came over to the house again yesterday to help me out. Thanks AGAIN David!! Bpape/Bryan is finishing up what I need for accoustics in the room. I'll post his findings once they are completed.
Well, onto the progress pics. I decided to put together a quick "How To Build a Column" guide. My methods may not be the fastest (or best) way but worked well for me.
Step 1: Line up the (2) side pieces up on edge. Try to put the best edge up as that is the one that will butt up against the front piece. Also, note I have a spare sheet of MDF on the garage floor. This creates a very flat surface and makes the final product a lot easier to nail together.
Step 1a: Here is another shot of the sides sitting up on edge and aligned.
Step 2: Lay the top of your column on top of the side pieces. Be careful as you move the side pieces under the top piece for alignment since balance is the key here -- one wrong move and this thing will fall down like a house of cards.
Step 2a: Here is another angle of the front piece sitting on top of the side boards, held together only with gravity.
Step 3: I used a 2" brad nail to attach the top to the sides. I spaced the nails about every 3 - 4 inches. Be very careful to keep your brad nailer perfectly aligned with the side boards as those 2 brads have a tendency to shoot out the sides if it is not.
If you look closely, you can see the little brad nails. I chose to use brad nails vs. screws because it would be less work to prep the MDF for the future maple veneer. It also reduced build time substantially. Because the nails went into the edge of the side boards, the MDF will easily split with any substantial side-to-side pressure. Side support braces are needed to ensure column strength (see next pic).
Step 4: Carefully flip the column onto its belly. I used a 2x2 pushed into the corners to get the strength these columns needed. In order to keep the 2x2 tight against the side and front piece for nailing, I created a quick temporary wedge. Again, I used the 2" brad nailer and spaced the brads about 6" apart. I attached the brads on the sides and from the top for extra support.
Final: Here is the front of the finished column. It is 8' tall x 16" wide x 6.25" deep and weighs in at 56lbs. That MDF is heavy but the column is very solid. The second pic is the back of the completed column. You can see the 2x2s that I added for extra support.
Ahh, finally --- (6) of the needed (8) columns built for the HT lined up like solders. If you look closely, you will notice the side cutouts for electrical and AV outlets. Because all my walls will be covered with fabric panels, I did not want to break up the clean lines with any outlets. All these outlets are on the column sides and face the rear of the room. The MDF to the right is for the front columns. I will hopefully get to those tonight or tomorrow.
I must take a small "break" from HT construction to build something WAY more important. Does anyone remember the Pinewood Derby? Well, it's now called Derby Days and my daughter is in Y-Princess (formally called Indian Princesses). The race is in a few weeks so I must make a car. It should be fun to build and I'm SURE this car will be painted pink! Still have to come up with a design for the car.. so any ideas would be appreciated (remember this is for a girl). I was considering a Cinderella carriage theme but I think the wind resistance on it will slow it down too much.