Hi Terry,
Each well is completely filled with XPS foamcore (to depth - 2.5mm), and then (to be) faced with 2.5mm ply (40mm x 915mm) faces. Faces were cut at the home center; we cut our own fins. I will post more pics in the next few days. If built so that the bottom of the well is 'down,' as long as the frame and backing are level, yes the foam stays, and in the right depth and place. It helps to use bar clamps to keep things neet, and we also 'tamp dowm' every so often, because there is a bit of movement when you are working on it. We put some glue on the inside of the frame, and there is glue between the foam and divider(s).
The spacers (additional XPS 40mm chunks) are necessary to keep the fins square, especially with the deep wells, but we found also with the medium wells. All will be removed (easily, with a couple of pallet knives one on each side) after the glue dries, yes.
The faces will be glued and we need to put some weight on them while drying so they don't curl. We will use scrap wood for this, or small rocks (less than 4cm). After the array is complete, a radius plane (hand tool) will radius the frame (can be done before too). Then we use an air sprayer to shoot stain (dark walnut). The type we have gets shinier with each coat.
So with luck the arrays will look more pleasant in the end. I am also considering shooting lacquer or poly over the dried stain, but this is likely overkill and could create issues. Though it might look sharp.
Quote:
Originally Posted by terry j  does the foam stay? (ie fill the void below) or just spacers till the glue dries. What you will see is the 2.5mm ply yeah? |