In addition to my video on Youtube on the subject, I am going to include step by step instructions on how to build your own. Over the years, I have refined and made the original better (I’ve sold about 75 of them).
So, here is the procedure for building your own:
Step 1 – Select some clear boards that are 1X6 with no knots or twists, that are 8 feet long.
Step 2 – Crosscut the boards to 51 inches and 27 inches (this will allow you to insert standard 2X4 plexi ceiling sheets for light fixtures later on).
Step 3 – Rip the boards to obtain 2½ rails (you will get two from each board).
Step 4 - Round the ends first with a table router. NOTE: Rounding the end grain first will allow you to clean up any chipping caused by the router, when you round the edges on the long sides).
Step 5 - Insert the ends into a jig (or band saw or dato blade) to cut a lap joint on the ends of each rail. Exactness is critical here!
Step 6 – Raise the blade on your radial arm saw to cut the lap joints out of the board.
Step 7 – Carefully, plunge cut the rails on the thin sides, to put the plexi panel grooves into each rail. The reason I plunge cut these is so that the gap will not show on the end of each rail (you may not care, but I didn’t like the look of the earlier model).
Step 8 – Drill a hole exactly in the center of each lap joint.
Step 9 – Prime and paint… I use spray paint on mine.
Step 10 – Use “T” nuts, washers and short bolts to assemble the rails. Loosely bolt 3 rails, then insert the plexi panel, then attach the 4th rail and tighten.
Step 11 – Attach your hinges, and set up your façade…
So, here is the procedure for building your own:
Step 1 – Select some clear boards that are 1X6 with no knots or twists, that are 8 feet long.
Step 2 – Crosscut the boards to 51 inches and 27 inches (this will allow you to insert standard 2X4 plexi ceiling sheets for light fixtures later on).
Step 3 – Rip the boards to obtain 2½ rails (you will get two from each board).
Step 4 - Round the ends first with a table router. NOTE: Rounding the end grain first will allow you to clean up any chipping caused by the router, when you round the edges on the long sides).
Step 5 - Insert the ends into a jig (or band saw or dato blade) to cut a lap joint on the ends of each rail. Exactness is critical here!
Step 6 – Raise the blade on your radial arm saw to cut the lap joints out of the board.
Step 7 – Carefully, plunge cut the rails on the thin sides, to put the plexi panel grooves into each rail. The reason I plunge cut these is so that the gap will not show on the end of each rail (you may not care, but I didn’t like the look of the earlier model).
Step 8 – Drill a hole exactly in the center of each lap joint.
Step 9 – Prime and paint… I use spray paint on mine.
Step 10 – Use “T” nuts, washers and short bolts to assemble the rails. Loosely bolt 3 rails, then insert the plexi panel, then attach the 4th rail and tighten.
Step 11 – Attach your hinges, and set up your façade…
