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Discussion Starter · #1 · (Edited)
Making a panel surround for a small wall. It is opposite the understair closet I did recently. It will complement the closet using the same panel configurations and heights. She has a nice stained glass that is about 21 x 41 and I will make a frame for it and it will be suspended inside of the window area of the wall.

The darn wall is like 5/8" out of plumb so that it makes the window hole waaaaay out of square. I've just made the surround so that it will fit over it and just have spaces where it's out of plumb. I'll use the ole spray foam trick I use to install trim around a lally column in a basement. When it dries it locks the pc in place.

Here is the CAD drawing of what it'll look like.


Here is the wall itself

front


back


Put the finishing touches on most of the build today, stayed a little late so I could put it together.











I have to make the frame for the stained glass tomorrow.
 

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Discussion Starter · #2 · (Edited)
Damn that took way longer than I expected. Simple, make some molding and make a frame out of it. Then make a frame to fit in the frame. And then a bunch of other stuff that took a lot of time. Needed to go to the hardware store for some 5" machine screws and some "T" nuts. Got the screws but the "T" nuts seemed to be elusive. I've bought them there before and know about where they are. They have all those pull out boxes with hardware. Looked for about 10 minutes and I couldn't find them, there was an open slot with no box. Asked the owner where it might be, no clue. I guess someone stole the whole box of them. Went to another hardware store and got them. What BS.

Here is the jamb with the frame that will hold the stained glass


Here it is back in the wall unit, front then back




Close up of how the frame is attached, front and back




Here is the inside of the frame, the pinch point for the stained glass




This is the frame that fits into the frame. It will hold the stained glass in the main frame


Had to do some cutouts to go around the screws. Used the spindle sander.
 

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Discussion Starter · #3 ·
Went over and did the pre fitting. Prime and paint tomorrow.










 

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Discussion Starter · #5 ·
Yep. I don't have to do it this way. But it's a cabinet finish and a pain install. The wall is out in every direction. It leans 5/8", the hole is 1 1/4" out of square, the back wall has a 3/8" curve in it, the wall thickness goes from 4 3/4" to 5 3/8", the floor is out of level by 1/8" and the floor thicknesses are different by 1/8" from the front wall to the back wall and the end by the stone is out of plumb by 3/4". :eek:

And not paint, I need to finish it. Big difference.

First, I wasn't positive it would fit correctly, and if I needed to modify it I can easily do it unpainted. 2nd when I come to install it (painted) all I need to do is put it in place and use some expanding foam and clamps and wait an hour and I'm done. The only time I really lose on this is the extra trip over there.

I don't do this often, but when it comes to lots and lots of scribing I don't want to screw up the paint job. Conversion Varnish does not touch up well at all. Especially white.
 

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Paint was your word, not mine. 😜

How do you deal with the joints, and seams during re-assembly on the job?
 

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Discussion Starter · #8 ·
Paint was your word, not mine. 😜

How do you deal with the joints, and seams during re-assembly on the job?
I use a special joint that hides any seams, full beaded corners.
 

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Discussion Starter · #10 ·
How do you charge for a job like that?
Just like any other custom job. Figure out the materials and how long you think it'll take to complete. Just because I have the extra step of the pre install doesn't make it that much harder to calculate.

The hardest thing is to figure out how you're going to build it with all the out of plumb, square, not straight, varying thickness and whatnot. Spent over an hour putting this into my CAD. Thank goodness for a laser. Would have been easier with 2 lasers
 

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Discussion Starter · #11 ·

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Discussion Starter · #13 ·
I learned to use it when I did basements. Wrap a round post with a square box and put in the foam. When it dries it holds the post cover steady.

I built the inside of the surround to be 5 1/2", the wall at its thickest is 5 3/8". But at it's thinnest is 4 3/4" So there's some space in there. And since I don't want any nails into the paint I'll use the foam. I doubt this will be removed anytime soon.
 

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I learned to use it when I did basements. Wrap a round post with a square box and put in the foam. When it dries it holds the post cover steady.

I built the inside of the surround to be 5 1/2", the wall at its thickest is 5 3/8". But at it's thinnest is 4 3/4" So there's some space in there. And since I don't want any nails into the paint I'll use the foam. I doubt this will be removed anytime soon.
I don't think it's going any where easily...

All my wraps have been traditional. The only unusual thing I've used foam for is when an electrician's helper did a sloppy old work box cut in into plaster and lath. Put about a whole can into the wall to keep the box from moving. When he figured out I could fix sloppy work, it didn't go as well.:no:
 

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Discussion Starter · #16 ·
Installed it today, came out nice.









Here is the beaded corner I use to assemble my prefinished stuff on site.
 

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Discussion Starter · #18 ·
Thinking about what?
 

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Very nice Leo, Its more like a privacy partition. I wonder why they didnt go with a full glass.

Did you do those cool stair acces panels too?
 

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Discussion Starter · #20 ·
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