Orig posted June 6, 2011
The saga continues…
The cyc wall is really coming together, and it’s pretty exciting to think we will no longer have to travel to shoot in the studio.
Day 2 was all about the swoop, and although a bit frustrating at times, the build was really rewarding.
We first started with the ribs which were all cut out on a CNC machine by Mystic Scenic in Norwood MA. It really was the right decision to have Mystic (thank you Eric!) design the wall. Once we started building, it was clear just how much time was saved having the ribs pre-cut.
We dry-fit the ribs against the metal studs just to make sure we had enough, as well as ensuring all the mathematics were perfect. Once we knew everything was going to work, we anchored down a 2×4 to the floor so we could key the ribs.
Once this was done, it was just a matter of screwing the ribs to the studs, and then doubling up the ribs every eight feet in order to lap the wacky wood.
From here, we inset the stringers 90 degrees to the ribs to give added support to the face of the swoop.
One interesting thing to look at is how the ribs on the two walls are attached.
The ribs on the long wall were going to sit flush against an existing wall which would cause the wacky wood (for the swoop) to leave a gap the width of the wacky wood (.25″) Not that big of a deal… This gap will be filled with plaster.
The short wall is easier and is done slightly differently. For these ribs, I had Mystic add three extra inches to the vertical side. Since the short wall had no drywall on it yet, the extra material would allow the ribs to go into the open wall and be screwed to the existing studs. This basically allows the wacky wood to run right up flush to the drywall making for a seamless transition that needs only a small amount of plaster.
Along with having Mystic Scenic design the plans and pre-cut the ribs, I also had them send over one of their master carpenters to lend a hand. While I was tackling the ribs and stringers, Harold (from Mystic) kicked into high gear and went to town on the hardest part of the wall… The center compound curve.
This is basically done the same way as the straight wall, but with a bit more math and a lot more parts. In order to get it just perfect, we used mesh stapled to the ribs. Once it was all secure, we would call in the plasterers and let them hit it.
For the cherry on top, the plasterers stopped by to check out the work and tape the seams in preparation for an early start. I cant wait till I can start painting!
All in all, it was an insanely productive day. I was wiped, but satisfied that we did a great job and didn’t cut any corners (literally!)
Next post, the plastering!Back to Blog