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 Stretchhouse.com. 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)