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Cut the 1x2x6 wood to the measurement of the outer rim. In my case the two long pieces were cut to exactly 48” and the two short ones to 21” 7/8”. Make sure that you measure twice and cut once, or you may need to make another trip to the hardware store.
As you can see in the picture, I am using tension clamps to jig the pieces of wood in place. I also liked using the very long G Clamp to apply pressure to the segments as I was gluing them together. Here are my steps after cutting the wood:
- Put some white carpenters glue on each short segment end.
- Apply pressure towards the short segment with the long G Clamp.
- Secure the wood with a wood joiner (it can also be the Corrugated Fastener 38334, but I hate these bastards! All they do is ensure your finger nails are now transformed into hammer targets).
- Once the four corners are secured, de-clamp the frame from the hardboard and turn it on the other side (you want the wood joiners to be hidden).
- Apply a fair amount of glue to the hardboard sides (where the wood frame will reside) and place the frame on top. If glue squirts out, clean with a damp cloth.
- Apply as much pressure as you can.
- Carpenters all over the world will figure me as a frigging exaggerated carpenter. In case you are wondering, I am not a carpenter but an electrical engineer, so I am awfully glad (as well as surprised) that the frame came to be at all!
This is my small frame. I did three of these and they were positioned besides the large frame.
This is my large frame, the one I placed on the same center of the room, behind the studio setup.
- Let it be for at least 12 to 24 hours, while the glue cures. I left them overnight and resume work on them after returning from work, but sometimes did them on the morning as well, so 12 hours should do.
- But if you are a hasty scum bucket of evil and can not wait that long without your heart racing toward cardiac arrest, I recommend you work on cutting the foam, which is quite doable at this time.
- Use a very sharp blade and a long ruler to get this done. Notice in the picture below the blade is totally exposed. This clearly occurs only to a moronic fool, reinvigorated with false hopes of invulnerability, after seeing the “Superman Returns” movie. Be warned that although the foam is very gentle and easy to cut, so is your skin. I was lucky enough not to get cut while using this idiotic method. But if you cut yourself, don’t come in on suing me! Remember I only have money to spend on Guitar Center, so be warned!
The red on the ruler is not my blood, by the way...
- Once the frame is ready, put as much glue as you like on the exposed hardboard.
- Place the cut acoustic foam and leave some weight (like an inverse foam piece with some weights) on top of the entire assembly.
- Let it rest overnight.
- Place on your wall as you see fit!
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