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Haha yeah, I borrowed a pneumatic combo brad nailer / stapler and a little compressor from my next door neighbor - worked well as a brad nailer to speed up the panel construction, hopefully works well for fabric stapling too. =)
How big is the crown of the stapler? I originally used a combo brad/stapler but the crown was too small. Only 6mm from memory. I bought a new stapler that had a 12.8mm (1/2") crown. I found the large staples evened out the tension on the fabric.
 

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Discussion Starter #86
Did you get any of the fabric up over the weekend?
Thanks for checking on me Greg - yup, got some work done, my fingers and shoulders are tired.

Got started on covering the soffits with fabric (black 16 oz Commando Cloth) this weekend. I started with a Harbor Freight combo brad nailer / narrow crown (1/4") stapler that I borrowed from my neighbor, but after about 6' of soffit, it started jamming, and then lost pressure, couldn't figure out how to fix it. Looks like I owe him a new one. So I went to HD and picked up a Porter Cable narrow crown stapler, and that has worked great.

Here is my temporary fabric cutting station - I had the triangle scraps sitting on the ground already, just screwed them to a 2x2. Notice the nice fist sized stain on the right side of the roll, goes all the way through apparently - would have been pissed, but (a) I didn't need the full width, and (b) it was far cheaper at $3.99/yd than anywhere else I found.



This stuff is extremely opaque, so there was no need to worry about doing anything to hide the reflective foil on the FSK. Its not real good at the blow test, but since I'm using it over bass trapping, not too concerned. Its also quite heavy, so required some muscling around to get it tight across the wide soffit underside - hope it doesn't sag over time.

First step was to hang the fabric up onto the tray edge using big binder clips - had my son help hold the 24' length of fabric while I clipped it up. The camera flash really washed out the colors, the ceiling is very dark brown, and the fabric is black.



Started stapling at 1" from the top of the tray edge (will cover with some black trim), and then to the furring strip at the edge of the soffit where it meets the wall. I will glue down the strip of fabric above the staples and over the tray edge top - not sure what glue to use yet, don't want overspray, so 777 is out. Maybe just white glue. Or contact cement.





almost done with the right wall:



right wall done stapling up, and trimmed off the excess:



Cut out the holes for the recessed lights, and added the trim:





left wall going up:



left wall trimmed, still need to cut out for the lights, and an access panel to get to the outlet that the rope light is plugged into:

 

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Discussion Starter #89
nice job brad :T
Looks awesome. That is going to be one sweet theater.

I like the color, that second photo is probably a decent shot of the true colors? :dontknow:
Thanks guys! My pictures aren't great, hard to get a picture that makes the brown ceiling dark enough without making the commando cloth even blacker than it really is (it is black, but not pure jet black really) - this one comes the closest:

 

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I started with a Harbor Freight combo brad nailer / narrow crown (1/4") stapler that I borrowed from my neighbor, but after about 6' of soffit, it started jamming, and then lost pressure, couldn't figure out how to fix it. Looks like I owe him a new one.
Let this be a lesson to everyone. Never buy or borrow a tool from H***** F******. If you buy one, it will break before you finish the job. If you borrow one, you will most likely buy a new one for the borrowee. I'm a General Contractor and every tool we've ever used from HF has broken. China [email protected] Porter Cable was a solid choice.
 

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Discussion Starter #93
Hehe yeah, I learned my lesson a while ago with them - bought a drill press from them to save money - well, it still works, but the collar on the adjustable table is cracked, so it won't hold steady against any significant pressure, and the switch is permanently stuck "on", so to turn it off, I have to unplug it. :rolleyesno:
 

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Hehe yeah, I learned my lesson a while ago with them - bought a drill press from them to save money - well, it still works, but the collar on the adjustable table is cracked, so it won't hold steady against any significant pressure, and the switch is permanently stuck "on", so to turn it off, I have to unplug it. :rolleyesno:
You will not save money with them (unless you are going to use the tool once or twice) in the long run. Some of their hand tools are decent, but their power/pneumatic tools are junk. Stick with Bosch, Porter Cable, Milwaukee, Makita, Dewalt, etc.
 

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Discussion Starter #95
Pics! Here's a few pics of the soffit as of night before last - still a couple places where I need to trim and tuck and such, but its getting close. The uneven shadows in the rope light are because there is still some fabric sticking up on the inside of the tray that I either need to trim off with a utility knife or glue down or both. I wonder if a glue stick would work, or maybe just a bead of white glue - don't want to do the contact cement back there, would be hard to work inside the tray.

I added the eyeball trims on the screen lights last night, but didn't shoot a picture of it.





 

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Discussion Starter #96
upholstery time

Last night I had precut some of the vinyl I'm putting on the column sides, and couldn't wait to try it out - so I had at it on my lunch break, managed to get the sides of two of the columns done - the stapling for these sure goes quicker than the soffit, much easier to handle:

I stapled on the first side before I started taking any pics of the process:







From the start - cut a panel a bit oversize to allow for wrapping/stapling:



stapled the inside edge:



flipped it over and started pulling the material tight and stapling:



done stapling all around:



trimmed off excess, and used xacto knife to cut holes where the mounting screws on the sides go:



right side column done and test fitted:



left side column done and test fitted:



Not screwed down yet, because (a) they will need to be out of the way when the carpet is installed, and (b) I need to cut an inch or so off the bottoms to clear the carpet / pad. Shouldn't be too bad, add a piece of bracing a little higher, cut away the vinyl with xacto knife, and then saw off the bottom. Trim will be covering top and bottom.

Will also need to sand the face panels some, as I didn't leave quite enough clearance for the vinyl and speaker fabric in the nooks.

Fun!
 

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Discussion Starter #98
I must have missed that..What type of vinyl did you use?
It looks to have come up a treat! :T Is this an alternative to staining?
Its Amarillo Deadwood faux leather vinyl, from www.allvinylfabrics.com. I'm quite happy with how its coming out. Yeah, sort of an alternative to staining - I stick-built the columns, but still wanted a sort of rich wood look, hence the shade of vinyl and a little pattern to it. Should allow me to stuff the columns and get more bass trapping.
 

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Ah yes.. I see it's an upholstery vinyl..That's a natty idea..:T
I've never thought of using that sort of vinyl as an alternative to paint or stain!
Looking at my local supplier, there's a huge range of colours and patterns..
 

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Discussion Starter #100
more column upholstery, fabric behind screen

Finished up the rest of the column sides on Saturday - here are the front and side columns, with the face frames in place (spent a couple hours today belt sanding the edges to make them fit after the vinyl was added):



rear corner columns:



all of the right side columns:



Saturday afternoon, I got the black speaker fabric up over the OC 703 behind the screen wall - the speaker cloth is 102" width, so no seam, covers top to bottom (well except the part on the lower left where I accidentally ripped the fabric, and had to put a patch over it - oh well, its behind the screen wall, so I didn't care enough to do a pretty fix). Looks a bit smudgy, I need to go over it with a lint roller I picked up at Staples:



The LCRs sit on Rubbermaid adjustable shelving - the shelf support rails are attached to vertical 2x4s laid flat, with channels routed in them - allowed me to attach the fabric to the 2x4s after I cut out to expose the rails - edges of the fabric are glued to the inside of the channel with contact cement.

Closeup of channels that the adjustable shelf supports sit in (may need to touch the gold screw heads with a sharpie):



And I received the recessed fixture socket extensions I ordered, so I put the eyeball trims in:



Next step will be to paint the column face frames black, then cover them with speaker fabric. Oh, and take care of some cleanup on the soffit fabric, trim etc.
 
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