This weeks project heavy sound proof doors.

[adidat]

Hi Guys

Thought I would do a quick WIP of a project i'm on at the moment, last time I attempted this it came to an abrupt ending as i blew myself up and had 2 months off work, about a year ago!

currently working on two soundproof doors. They have been spec'ed at a solid construction weighing a minimum of 50kg per Sqm so each door will weigh about 95kg when finished :shock: :shock: :shock:.

to get the desired weight we used a fd60 fire door with a sheet of 12mm stuck on one side and 18mm on the other. Then lipped in 40mm meranti with a special frame built around it to minimise gaps and allow for specialist sound proof seals to be installed.


Thats the hinge side, showing the central sound barrier thing that should hopefully lock in to the door on completion!


Thats the slam side, the little black bits show the location of the seals.


The process of sticking the mdf down, give a liberal coating of PU glue then using a bit of wood, drag it all around the fire door so that all the face is covered with thin even coating, then add the sheet of mdf, then 7 cauls with clamps at each end. Initially i was planning to screw it down with 20 screws, but this was far easier and doesn't leave me with 80 screw holes to fill and sand!!


So at this point I realised wrestling these monstrosities on to the table saw was going to be a mission, i'm never that hard to persuade to buy new tools especially if there lime and blue and come from Germany!! (hammer) (hammer)


The new saw made a great job of it, and by resting it on the timber and running it along the back of a rail I was able to cut all 84mm leaving 1mm to spare!


This off cut shows how good the saw cut is, and also helps explain the construction, the hardwood is the fire door which comes faced in 6mm mdf then i have added two pieces of mrmdf.


cut all my lengths of meranti, just need to plane down to correct sizes and run my profiles, i'm not going to say how they will be done as it involves some naughtiness with the table saw!! :evil: :evil:


Thats all for now folks!!

Adidat

 

[Nelsun]

Soundproof? Bombproof as well I should think... and I'll bet the MFT had a bit of a WTF moment with all that going on it

Does the HK85 come with a spare pair of [brown] trousers included?

 

[adidat]

The other door I glued up on tough built c650 trestles and it didn't budge. There fantastic trestle's, where as the mft wobbled all over the place. Not knocking the mft as it's an excellent portable work bench. Just not really suited to the job.

Yes things could go very wrong with the hk85 but if you spend a bit of time getting set up and just go slow and steady you shouldn't have two many problems.

Adidat

 

[ColeyS1]

Wowsers, they are monsters !!! Looks like you're really well set up. That vice jaw looks a beast aswell [SMILING FACE WITH OPEN MOUTH]
Just one thing I did notice. I wonder if the frame and door edge may have benifited from being angled ? May have helped reduce the amount that needed planing off for the leading edge, smaller gap?
Best have your weetabix when it comes to lifting them :lol:
Coley

Sent from my SM-G900F using Tapatalk

 

[adidat]

Yeah the drawings don't show the leading edge that's going to be machined.

Just made up these to get the rail in the right position to get the door side nice and perpendicular was about 3mm out one corner.



Adidat

 

[RobinBHM]

We used to make soundproof doors for radio and music studios.

Usually the spec was a standard FD60 veneeered door with Royd and Tucker magnetic seals around the sides and a drop down seal at the bottom.

We found generally the studio designer would set out the studio so each one had a lobby with a sound proof door, then the actual door to get into the studio. The lobby acts as a sound lock and had a big impact on sound.

The door is often not the limiting factor, when sound proof rooms are built, it can be tricky to isolate the floor, walls and ceiling from the rest of the building.

Gone are the days when studios had to be built to a BBC standard with lead lined and sand filled doors....

 

[adidat]

I'm not really had much to do with the room. It's for a drum studio in a basement we have dug out. Fairly wealthy customer.

Adidat

 

[Hot stuff]

What hinges are you using and how many of them?

 

[adidat]

4 big b@sterds rated to 120kg. Similar to parliament hinges but not with the corners cut out if you get me!

Adidat

 

[sunnybob]

"last time I attempted this it came to an abrupt ending as i blew myself up and had 2 months off work, about a year ago!"

Forget the dam doors, input, charley 5 needs input!

 

[thetyreman]

this is fascinating adidat, I'd like to make a similar door for my studio, it's a shame I can't see the photos though, would have been really useful, any help would be appreciated.

 

[AndyT]

this is fascinating adidat, I'd like to make a similar door for my studio, it's a shame I can't see the photos though, would have been really useful, any help would be appreciated.

I've just installed "Photobucket Hotlink" - https://addons.mozilla.org/en-US/firefo ... x/?src=api - as mentioned recently on another thread, and it's working for me - all of Chris's photos are showing again.

 

[thetyreman]

this is fascinating adidat, I'd like to make a similar door for my studio, it's a shame I can't see the photos though, would have been really useful, any help would be appreciated.

I've just installed "Photobucket Hotlink" - https://addons.mozilla.org/en-US/firefo ... x/?src=api - as mentioned recently on another thread, and it's working for me - all of Chris's photos are showing again.

awesome, just installed it on chrome and it works a treat, as well as firefox.

 

[adidat]

Thanks guys also that sounds an interesting add on, can I get if for chrome?

At some point I will try and re-upload my stuff but it's a bit of a daunting task, luckily I could save all 700 photos from photobucket. But still upsets me really 9 years hard work documenting my hobbies and job down the toilet.

As to the doors yes the customer where very pleased and they worked well together including some specialist accoustic seals. Just before I finished them I had my van cleared out by tea leafs so that didn't help....

Adidat

 

[thetyreman]

Thanks guys also that sounds an interesting add on, can I get if for chrome?

At some point I will try and re-upload my stuff but it's a bit of a daunting task, luckily I could save all 700 photos from photobucket. But still upsets me really 9 years hard work documenting my hobbies and job down the toilet.

As to the doors yes the customer where very pleased and they worked well together including some specialist accoustic seals. Just before I finished them I had my van cleared out by tea leafs so that didn't help....

Adidat

here's the link : https://chrome.google.com/webstore/sear ... x?hl=en-GB

it works for me.

you shouldn't need to re-upload them hopefully if people get the app.

 

[adidat]

thats fantastic guys really cheered me up!

im going to add it to my signature!

so nice to see my robert sorbys again!!!

 

[adidat]

been meaning to update this for a while, but with the whole photobucket scandal never got around to it.

Anywho seeing that some one is trying to make something similar, I thought I would post the finished pictures.

Customer was very pleased and they worked very well. I ended up fitting the hinges and frame to the doors whilst they where on the bench due to the weight ect, and the guys on site fitted the frames and humped them about, then it was just a case of fitting the ironmongery on site!

Adidat

 

[adidat]

One last thing, when i was making them, i was being massively harassed by the boss and architect to get the gaps non existent ect, ignoring my pleas that if they where to tight the seals wouldn't fit properly and cause the doors to jam.

This was of course the case so it meant i had to go on site and remove the doors and router in some grooves for the seals to fit. Made a lot harder due to the doors weighing in excess of 100kgs each and just had a fresh coat of paint that was still tacky....

Adidat

 

[thetyreman]

great to see the final installed door, looks good! =D>

did you have to reinforce the door frame? would pine hold that kind of weight?

 

[adidat]

I seem to remember that every other hinge screw on the frame was put into the concerete behind. And then 4inch screws into the door hinges.

Pine would be fine. Meranti was used as it paints nicely and easy to work with

Adidat