>> <Daniel.Ung...@gmail.com> wrote:
>> > On May 15, 5:57 pm, WilliamMLov...@gmail.com wrote:
>> >> I want to build light weight walls for a theatre production at my
>> >> church. I am looking for suggestions for the wall surface (panel)
>> >> material.

>> >> Background:
>> >> Here is what I need:
>> >> - The walls must be 12 feet high
>> >> - They must be lightweight
>> >> - They must be easy to setup and teardown and move to storage
>> >> - The walls should not warp while stored.
>> >> - The walls will be decorated will various things like paint, foam  
>> etc
>> >> as needed.

>> >> Here are my current thoughts:
>> >> - I am thinking of building walls in 12 feet by 4 feet sections. This
>> >> is a manageable size and materials are often sold in 4 by 4 or 8 by 4
>> >> foot sections so 12 by 4 should be easy to construct.
>> >> - I plan to join wall sections together so each section should easily
>> >> attach to neighboring sections.
>> >> - I am thinking of some sort of panel material attached to a frame.

>> >> The Frame
>> >> I think I have found satisfactory frame materials. Since wood tends  
>> to
>> >> warp, I am thinking of angle aluminum or "slotted" angle steel.
>> >> Slotted steel has many holes predrilled in it so it is quite light  
>> and
>> >> can be easily bolted to the neighboring sections.

>> >> The Panels
>> >> Here is where I need help. Normal plywood is too heavy. I have seen
>> >> corrogated plastic. This has some value but seems flinsy.

>> >> Can anyone suggest other possible panel material and how I can optain
>> >> it?

>> >> Thank you

>> > Hello.

>> > My first concern is the idea that you want to use aluminum to make the
>> > frames.  I would highly suggest against this for two reasons.  First,
>> > aluminum would not be cost efficient.  Second, unless you are planning
>> > to bolt together the aluminum pieces, you will need to find someone
>> > who can weld aluminum.  Ultimately, going the route of aluminum would
>> > be very difficult, and I wouldn't suggest it.

>> > My suggestion would be to make a Broadway-style hard-covered flat
>> > (Another person has replied who describes Hollywood vs. Broadway flats
>> > as being hard-covered vs. soft covered (Muslin).  He is not entirely
>> > correct; Broadway vs. Hollywood deals with the frame, not the panel
>> > material).  Create these out of 1x4 and 1/4" Lauan plywood.  First of
>> > all, rip down the 1x4 from 3.5in to 3in (This will save some weight.
>> > You can go down to 2.5in, but I would not suggest it for something of
>> > long term use).  Frame the frame with the 1x4 flat, NOT ON EDGE.  I
>> > would assume that you are going to use corner blocks and keystones to
>> > frame it.  Make sure you leave all corner blocks and keystones 1" away
>> > from the edge of the flat.  This way, if you ever make a 90 degree
>> > corner with two of your flats, they will mesh flush and not have the
>> > blocks and stones in the way.  Use 1/4" Lauan to cover the panel.  Be
>> > sure to have a toggle at the seam where the 8' piece and the 4' piece
>> > meet.  Glue and screw (or staple) the Lauan to the frame.

>> > Do not worry about weight.  One strong person or two middle strength
>> > people can carry one of these.  Depending on the humidity, weather,
>> > and how the flats are stored, warping may or may not occur.  If you
>> > pay special attention to the quality of wood you buy and the
>> > construction of the flats, you should have little or no problems
>> > storing them almost anywhere.

>> Or use 1/8" ply, & double skin the central 4' of the flat, very stiff ,  
>>  
>> you can still clamp them together easily & lighter.- Hide quoted text -

>> - Show quoted text -

> All these posts are very helpful.

> I did not know about 1/8 plywood Thanks for the tip.

> Question: what do you mean by "double skin"