2002 WALL HOW-TO
I'm getting lots of questions about haunt walls. Here I will attempt to document how mine were put together.
WARNING: This is a labor intensive, heavy, expensive method. BUT, the walls are VERY STRONG and reusable in different configurations each year. YMMV.
Basic Design
OK, there are only 2 types of "panels". A Flat section and a corner section. A corner is built from 1 flat panel and 1 corner. Let's start with the basic design diagram, and label some types of "corners and intersections" to make life simpler to talk about...
The three panels marked A1, A2, and A3 are just regular "STRAIGHT PANELS". The bolt together in a straight line. In case you didn't figure it out, the scale of this diagram is such that each one of the little border boxes around the picture is 1 foot. So, 4 of the little boxes is 1 panel (4' width of a 4x8 panel, and the walls are 8' high - see how simple this is?) Heh heh.
Now, look at "B". We have a "Corner Intersection" since B needs to bolt up to A1. To do this, we use 1 "CORNER PANEL" (in this case B), and 1 "STRAIGHT PANEL" (in this case A1).
You'll see more of this with some detailed drawings in a sec... but first, let's get the last type of intersection out of the way. The "T-intersection" . Look at area C1/2/3. C1 is a "corner panel". C2 and C3 are "straight panels". When I want to make another turn, C4 is just another corner panel. (C3/C4 is really just another "B" type corner - i just threw it in here to keep things confusing.
OK, clear as mud? Great! Let's look at detailed drawings.
WARNING: NOT TO SCALE! (hee hee)
STRAIGHT PANELS
Each "Straight Panel" uses one 4'x8' sheet of plywood (I used 3/4", but you may wish to keep it cheaper and lighter by using 3/8" instead - again, YMMV). I used BC grade at first, until I realized that it's SCARIER (read: cheaper and no one will notice) to use CD grade plywood. Ask the guy at Home Depot to show you the difference if you don't already know. It'll make his day to actually be able to answer a "technical" question. Argh.
Now, as you can see, I use two 2x4 studs, one on each length of the panel. Secure these with wood screws. Use galvanized if it's going to be outside in the rain. Use stainless if you have lots of free cash (and send some to me!).
STEPS so far:
1. Simply place the panel across a couple of carpentry horses
2. Have a person at each end hold the stud up to the bottom of the panel
3. Each person screws through the top of the plywood and down into the stud
about 6 to 8" in from their end. Avoid fingers if possible.
4. Put two more screws in for security (see diagram). Make sure the stud
pulls up flush with the panel. You may have to back out and re-do a screw
or two if it doesn't. This is reasonably important if you want to (a) keep
out light and (b) not have it all fall apart later. Heh.
Now we need to put the two end pieces in. You use a third 2x4 and cut it. No, not in half. Yes, I realize that half of a 2x4 is 4' long, and the end of the panels is 4' long, but you have to cut is SHORTER to fit in between the 8' studs.
FUN LUMBER LESSON: A 2x4 isn't 2"x4". It's 1 1/2" x 3 3/8". Don't know why. Don't care. Always true.
So.... You need to cut the third 2x4 into two 45" (48" - 1.5 - 1.5) sections. Hold these up and screw'em in with 3 screws from the top of the plywood just like you did on the sides.
ALMOST DONE
Now you need to put the bolt holes in the side sections. You will drill 4 holes, 2 on each side, 1/2" width. I drilled mine 8" from each end. This distance isn't very critical, but whatever you use, ALL PANELS MUST USE THE SAME MEASUREMENT. (Unless you don't care if it doesn't all fit together, in which case knock youself out and go wild!).
To ensure all is perfect, MAKE A TEMPLATE instead of measuring each time. Find a scrap block of 2x4 and measure and drill your hole. Then you can hold it up against the 2x4 and drill through the hole to ensure perfect measurements every time.
OK, put the panel away and start another! Keep building until you drop dead or finish however many you need, whichever comes first. I needed LOTS.
CORNER PANELS
A corner panel is just like a straight panel, but ONE (not both) of the side (8' long) studs is turned on it's side, and the bolt holes go thru the plywood panel and not just the stud. See the diagram if that made no sense at all. If you are still stuck, please email me and I'll say "ARGH - I can't figure out how to explain this better!!!!". Seriously, email me and we'll try to work through it. If we do, I'll post here whatever we ended up saying there!
JOINING THINGS TOGETHER!
Here's a pic of how straight panels "bolt together". Use 1/2" bolts, unless you drilled your bolt holes to some other size...
And another quick pic of how CORNER panels fit together. Same advice on the bolts...
HEADERS
Didn't write it yet, so you don't get to read it yet.
BRACING
Didn't write it yet, so you don't get to read it yet.
DOORS
Didn't write it yet, so you don't get to read it yet.
ROOF JOISTS
Didn't write it yet, so you don't get to read it yet.
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