Feature wall panels (finished/installed pic)

[Crazyraceguy]

Huge multi-panel feature wall. Most of the segments are simple laminated panels that get wrapped with aluminum angle as a proud edging. Three of them are distinctly different. They are built-up with a poplar frame, rabbeted to accept a glass front. The space behind the glass to be filled with plastic pellets. The slots in the frame are there to allow for filling/draining, so they can be changed.
This metal is exceedingly thick, but apparently all that was available in this size. Mitering that tight on that many pieces is quite a challenge. Three different miter angles on some parts.
Today I found out that there might be a problem with getting the glass for the biggest one. Apparently, 3/8"  laminated safety glass over 160" is not so easy.
The over-all of the assembly 140" high and 265" long. It might get fully layed out on the floor, that should be cool looking.

 

[Crazyraceguy]

more pictures

 

[luvmytoolz]

Nice work!

 

[Cheese]

Nice aluminum miters... [big grin]

What did you use to miter the aluminum angle and how are you attaching it to the wood?

 

[Michael Kellough]

Nice aluminum miters... [big grin]

What did you use to miter the aluminum angle and how are you attaching it to the wood?

Ditto, more info on this please.

[attachimg=1]

 

[Crazyraceguy]

I built that jig a while ago, to shorten the steel "in-wall" brackets that I often use in reception desks.
We have them fabricated by a local metal shop, in two sizes. (23"x23" and 28"x28") The smaller ones are the most common and we get them in quantities of 250 at a time. Sometimes I need them shorter, we I just cut them.
Cutting them with the shop's horizontal bandsaw works, but is a bit of a pain. I have also installed them long and cut them off in place with a porta-band. That works ok too, but requires measuring/marking.
When I got that Makita metal saw, I built the jig to simplify the task. It cuts that 3/16" steel very easily.
I just modified it slightly to work with the aluminum. It worked very well on the 1 1/2" material for the glass panels, but not so great with the 1" that goes on the back of the others, so I switched back to the miter saw.
I made a 45 degree fixture, to clamp to the saw, and still had to bevel 20 degrees more.
There are 3 cut angles 65, 25, and a few at 45.
As will become more apparent in these newer pics, they are screwed in from the back. There are a few in the edges too, just to pull some of the miters together or compensate for some of the aluminum not being perfectly square.
Ultimately, there are 21 of these panels, 3 per row, 7 rows high. Three of them have the glass, all others get the wood grain laminate.
I realized, when adding the pics, that none of them showed the screws.

 

[Crazyraceguy]

The whole stack, minus the ones that get glass.

 

[Crazyraceguy]

I don't know why I called the previous pic, "the whole stack"? it was only 5 or 6 of the 17 pieces. Maybe all of what was done at the time... [blink]
The glass came the other day, so I got these finished up. It might be a few weeks before it all gets installed, I'll try to get shots of that too.
It should be pretty impressive, the thing is huge

 

[Crazyraceguy]

The installers sent me a pic of this one today. All of the lines get blurred because of the digital format, but it looks good. The glass panels are to be filled with recycled plastic pellets

 

[luvmytoolz]

Looks great!