MY DIY Panels

[JCD]

I've had several panels of rigid fiberglass hanging around in my garage waiting to be turned into a form that was generally more aesthetically appealing. This last week I finally purr-ty'd them up and thought I'd share the process in pics..

Step one -- Buy the rigid fiberglass
Owens Corning's OC703 is the most famous of the fiberglass panels, but there are several other manufacturers. My is actually produced by John Manville Corp. I think it cost me ~$8-$9/panel.

Step two -- Buy the "covering"
I've been told that a loose natural fiber works best. I ended up going with burlap and found some here that I was able to get in Red and Black for less than $2/yard. It looks like the prices have gone up a little, but it's still a great deal.

Step three -- Build a frame
As with just about all things, there is more than one way to skin a cat. There are some that will use some spray on glue and just glue the fabric directly to the fiberglass. This may be a cheaper alternative than the route I went -- except, I have a contractor friend who ripped some scrap wood for me to use in the frame. If I didn't have that free source, I'd probably have to spend ~$10/panel in wood for the frame. This is based on getting the cheapest wood strips at Home Depot in my area -- I think it's something like $0.59/ft x 16ft (4+2+4+2). You might want to use something a little more substantial if you think the panels might get bumped into a lot. For me, all I wanted was to staple the fabric to them. Here are some pics of the frame construction.

Cut the pieces into two 2' and two 4' lengths


Glue the ends


Staple the ends to secure during the glueing process


Final frame


Step four -- Cover with the fabric
Pretty simple, cut the fabric so that there is enough to cover the panel. Since these are going to be used in my garage and will always be hanging on the walls, I didn't care how the back of the panel looked, as can be seen in one of the pictures below. If these were going to be in the main house, I'd consider using some sort of thumb tack instead of staples. They'd be a little less intrusive than staples. I'd also make sure the entire back of the panel was covered. One other concern has to do with the fiberglass itself. There are some that have some health concerns related to the fiberglass, specifically, that breathing in the fiberglass can cause some problems. If this is a concern, then you should wrap the panel in something like polyester batting -- the stuff they use for quilts. And now for the pics..

Lay the panel on the frame


Cover with fabric to find the amount to use


Flip the whole thing to the back side


Fold over the fabric on the sides


Stretch the fabric and staple to the frame so that there aren't any wrinkles


Just stapling the fabric to the frame





Completed shot of back


Completed shot of front


In the end, my total cost per panel is probably about $13 and took about 2 hours to build six 2'x4' panels and two 2'x2' panels. Compared to what I'd have to pay commercially, it's a pretty good deal. They're not as polished as the commercial products and I don't get the support these companies provide, but they should function pretty similarly.

Anyway, there you go.

JCD

[salvasol]

Good job ...

[Blaser]

That's Great JCD! You're giving us DIYers some ideas

[Prof.]

Nice job JCD...Simple and effective..

I used the black burlap on my panels...Works a treat..

[JCD]

Simple is definitely the word of the day. I was so worried that it wouldn't work out well or I'd mess it up somehow I probably wasted a year before getting those guys built. Whole purpose of the thread was to show how easy it really is.

One more shot -- a couple leaning against the wall in my house


If I get a chance, I'll put the red and black next to each other. I've always liked the black/red combo.

One more comment -- another reason why I liked using staples, I can fix it should I later find a wrinkle or what to clean it up for whatever reason.

JCD

[Prof.]

Are they going to be placed at first and second reflection points, or somewhere else?

[JCD]

Prof. wrote:

Are they going to be placed at first and second reflection points, or somewhere else?

I'll probably try to hit the reflection points off the side walls, then the ceiling. Depending on the results, I may try to hit the back wall too. I doubt I'll be using these for bass traps. I would probably have to buy another 6 or 12 pack to do that.

JCD

[Prof.]

JCD wrote:

I may try to hit the back wall too. I doubt I'll be using these for bass traps. I would probably have to buy another 6 or 12 pack to do that.

JCD

If you're putting some on the back wall, then you will need the type of insulation that has the FSK facing..
I think Bryan also recommends that they should be 4" thick as well..