The Birth of Super Screen, Part 2

Dear Constant Reader,

When last we left our heroes, there had been a lot of cursing down in the workshop at Stately Babydoll Manor. Armed with more plywood and a better plan, we began again.

Here’s one wing, marked for cutting. Those holes are so we can cut out the center, leaving a frame. Well, Scratch did all the cutting with the somewhat-scary jigsaw. My job was holding the plywood steady, which mostly meant draping myself across the sheet of wood, pressing down with all my weight and clinging to the opposite side of the sawhorse. That was kind of exciting.

Tada! A cut-out wing! I love the graceful curve at the top. It mirrors the curve at the top of the front frame. Almost like we planned it that way. You can see how it will eventually attach to the front.

Once everything was cut, it was time for painting. The color is “Champagne Mist”. Seems appropriate, no? After a couple of coats of paint, it was sealed with some clear polyurethane.

Here’s the nifty part. Instead of using fragile rice paper, we’re filling in the frames with Tyvek. It’s strong and waterproof. While it was probably overkill, the Tykev is both glued & stapled in place. After the glue had a little time to set, we trimmed away the excess Tyvek.

And after the Tykev went on the main frame, we added some lovely oak trim to jazz it all up.

When everything was more or less set, we took all 3 pieces upstairs to attach the hinges. That was when we realized that the screws that came with the hinges were slightly longer than the plywood was thick. That was actually a good thing for the front screen because it further secured the trim to the frame, but it was going to cause quite a problem on the wings. Can’t have nasty sharp bits of metal poking out of my Super Screen!

Fortunately we found just enough screws left over from a previous project which were slightly shorter and added a tiny washer to make them shorter still. All was well!

And what did this magnificent creation look like when it was completed? Next time, my patient reader…


Published in: on 1 October 2014 at 10:35 am  Leave a Comment  

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