Cylinder Cones

Todd Bougher at The Rock Family Worship Center in Alabama brings us these awesome background structures.

He started these structures by creating 2″ rings cut from 1/2″ MDF sheets (4’x4′). Then he ripped 1/4″ strips from a 2x4x10 piece of spruce. He used spruce because it has less knots and stays more true when ripped (he also chose straight lumber). He attached the rings to 1/4″ x 10′ strips with glue and long staples or screws.

He ripped 1″x2″x10′ plastic trim down the middle creating 1/4″x2″x10′ pieces. Using a chop saw, he cut sections to fit along the rings horizontally between vertical strips.

He found black big hole mesh and white spandex from You need the spandex that will stretch up to 7′ wide and need 3-4 yards of both types of material. The fronts were stretched and stapled with black mesh and back half and top with white spandex. You can see through mesh and light is reflected well off white spandex. Shadows of frame are seen on inside white fabric creating depth.

He used an air compressor with staple gun to attach structure and fabric. (You will regret trying to use a hand stapler.) Then he added white 1″ elastic down the sides of the structures to hide the loose material and make it look finished where mesh and white meet.


  • 1/2″ MDF
  • White spandex
  • Black big hole mesh
  • 2x4x10 spruce
  • Staples (long and short)
  • Glue
  • Elastic
  • Paint

10 responses to Cylinder Cones

  1. Wow! This is an awesome design that adds a lot of spunk to a stage!

  2. Wow. What a cool design. That is really cool.

  3. Big fan of Todd’s work. He is awesome.

  4. How do you create the effect on the back wall? Awesome stage set!

  5. There are so many different kinds of spandex….nylon, satin, metallic, regular, etc. Can you share what type you used?

  6. If you don’t mind me asking- what was the approx cost of this entire set up?

    This is a very cool design- one of my favs!!!

  7. Daniel Olanusi May 26, 2012 at 12:09 pm

    Awesome! are you avaiable for consultation on this design? if you don’t mind.

  8. Nice! Would like to know approximate cost as well?

  9. What is the waving background made out of?

  10. If you could please contact me I greatly appreciate it if there way that I can rent these from you for an event

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