Great build Wall itself: building instructions

build large Wall itself

Buying a Wall, does not constitute a great challenge and also the prices for this are not a serious obstacle. If the purchased Wall, however, hung, mostly the corners are off because they simply too thin and labilist. Those who value a more stable model has to reach much deeper into their pockets already. It is also difficult to find the desired size.

Better and cheaper in the end can be build yourself a large and stable wall. With our building instructions to build a Wall, which lies exactly flat on the wall and can accommodate a lot of important notes.

The instruction describes a collection with the size of 50 x 100 cm, but can also be adapted to your requirements. All you need for this is available in any hardware store and can also be ordered online.

Great build Wall itself: Contents

  • Tools and materials needed
  • Step 1 - glue cork
  • Step 2 - roughly cut wooden frame
  • milling recess with the router - Step 3a
  • saw cut on the table saw - Step 3b
  • Step 4 - rounding edges
  • sawing wood frame miter - Step 5
  • connecting frame with the Wolfcraft undercover Jig - Step 6
  • Step 7 - insert cork mat and fix with angle

Tools and materials needed

Collection can be pretty easy to build and identified tools need not necessarily be used. With a little imagination and own ideas, the wall can also be implemented elsewhere.

  • Miter saw (important)
  • Router / router table
  • table saw
  • Wolfcraft Undercover Jig
  • Cordless Screwdriver
  • notched trowel

The work required material should result in any hardware store, and can be purchased in larger batches to reduce costs in other projects.

Working materials for CollectionWorking materials for Collection

  • 9,95 € cork mat 1000 mm x 500 mm x 6 mm
  • 2.18 € hardboard 1000 mm x 500 mm x 3 mm (can be cut at the hardware store)
  • 8.50 € frame wood planed 2.5 m x 74 mm x 24 mm
  • 4.15 € Korkkleber (1 kg for other projects)
  • 6.08 € 4th low angle / flat connector pieces 140 x 140 x 2 mm
  • 2.15 € Pins
  • 1.95 € folding eyes (picture hooks)

Prices as at 3/2017 in the Bauhaus hardware store. Articles can also be ordered through Amazon.

Step 1 - glue cork

6 mm the cork is quite stable to favorable bulletin boards, cork but tends to break easily. Therefore, it is important to provide stability.

15 minutes remain for processing

This is done by the cork mat is glued to hardboard. When present, an old furniture back wall can be used. However, this has to be cut to size. A new hardboard size cost 2 € and can be cut to size at the hardware store.

For gluing the plates we use Korkkleber, which is available in different pack sizes. required maximum 500g. These are distributed evenly with a toothed trowel (painter department in hardware stores), and placed the cork mat. It should equally be working very closely because the cork mat is difficult to move. 

The processing time is about 15 minutes. During this time the cork mat must be positioned and the tool can be cleaned with water.

Spread evenly with a notched trowelSpread evenly with a notched trowelalign exactly Fibreboardalign exactly Fibreboard

Step 2 - roughly cut wooden frame

The first cut can be made coarseThe first cut can be made coarse

The wooden frame is later to be mitred, this must be before or milled however. To facilitate the cutting work and to avoid spalling, the Holzrahm in the first step is roughly cut to size.

Cut strips of wood: 2x 1150 mm and 2 x 650 mm

The lengths required resulting from the size of the cork mat and the strips of wood: cork mat + 2x width of the strips of wood. With a width of the cork mat of 1000 mm and wooden strips having a width of 74 mm is thus a blank of about 1150 mm is obtained. Since the wood strips purchased are 2500 mm long, one can also be easily shared, resulting in two pieces, each with 1250 mm. The supernatant is sawn off later. For the vertical bars two pieces, each with about 650 mm are needed.

On the router table can be milled accurately and safelyOn the router table can be milled accurately and safely

milling recess with the router - Step 3a

later the wooden frame has to absorb the cork mat is glued and to plan rest against the wall yet. For this purpose it is necessary to mill a recess. This should be enough for about two to three centimeters into the wood and be so deep that the glued on cork mat and the low angle can be accommodated. Thus, the cutting depth is 6 mm cork mat + hardboard 3 mm + 2 mm = angle starch 11 mm. 

For cutting particularly a router table is, since a good mood the boards and can be performed safely. So all the cut-outs at the four wooden strips are very even. Another possibility would be a router with rip fence, but the exact guidance is heavier and more complicated adjustment.

saw cut on the table saw - Step 3b

Whom no router table is available, the recess may on finished on the table saw. With disassembled guard but the work is not without its dangers. It should be extremely cautious.

In the first step, the heel width is sawed 3 cm. The blade should therefore be adjusted to an average depth of about 3 cm. "About"Because this level can be varied. But it is important that it is the same for all four strips. The rip fence of the table saw is aligned with the shoulder depth minus saw blade thickness. In a paragraph depth of 11 mm and a sheet thickness of 3 mm, the distance of the rip fence is accordingly 8 mm. Slightly more but does not harm - less, however, it should not be.

Without blade guard special careWithout blade guard special careRecess for receiving the corkRecess for receiving the cork

The second cut is offset by 90 ° with inverted dimensions. The cutting depth is now 11 mm and the rip fence is aligned to 3 cm minus saw blade thickness.

Step 4 - rounding edges

The exact depth of cut is importantThe exact depth of cut is important

For a better look, the edges of the frame timbers can be rounded or provided with a profile according to your wishes. However, this requires a router or better yet a router table is required.

As the edge shape should look like later, does not matter for the further construction and can therefore be selected as required. But it is important to accurately set the cutting depth of the milling machine. With a rounding of the router must be completely forming the radius, but may no market left on the surface. However, a minimally visible paragraph disappears during the subsequent grinding of the surface. The side of the thrust ring of the router serves as a boundary that provides the exact shape of the fillet.

be rounded only the later visible edges of the frame wood. The edges of the back are simply deburred.

sawing wood frame miter - Step 5

For the next step, a compound miter saw is needed. Similarly, a table saw with angle stop any other saw which operates on scribe would be available possible but should not be used. The work product is too vague, which will later be clearly visible when connecting the individual parts.

1. Cut The page miter1. Cut The page miter2. Align the cork on the milling edge2. Align the cork on the milling edgeMark 3. 5 mm next to the corkMark 3. 5 mm next to the cork4. Saw Both boards together4. Saw Both boards together5. sawing At the marking5. sawing At the marking6. Gap 2.5 mm6. Gap 2.5 mm

The setting of the required length is for many a problem, but there is a very simple method that helps and the rough and longer cut.

  1. With a 45 ° angle setting a cut is made just on the edge of all four strips. However, this pay close attention to the angle in the correct direction. The outer edge of the wood needs of these were the longer side. So all four strips are cut on one side.
  2. Then each create a long and a short bar with the paragraph up on the workbench and align the cork mat according to the image 2 thereon.
  3. On the other hand, the bar should be longer and 5 mm marked next to the cork mat at the heel. Who thinks to work very well, even less than 5 mm can use distance. The used here measure results (divided by two) the subsequent game, which has the cork mat in the frame. The scar must be done only on a long and a short board.
  4. For later precise assembly, the long and short boards are sawn each as a couple and for one another tense.
  5. On the miter saw dasa timber is aligned so that the saw blade exactly meets the scribe at the edge. At the heel, therefore the board is shorter than the scribe and longer at the outer edge. So the two long and two short planks are sawn.

In the following test should be all four boards zusammelegen and the cork mat with a gap measure fit of about 2.5 mm in the milled paragraph. (Images can be enlarged with a click.)

connecting frame with the Wolfcraft undercover Jig - Step 6

The Wolfcraft Undercover Jig can not only be used for rectangular connections, but also to connect bars long.

However, the space available is relatively low and it must be taken here that the inclined bore can not be seen at the outer edge. If necessary, the holes should be performed at each of the longer boards In the case of the outlet of the holes are located in the upper and lower side of the Wall and I not visible in the suspended state.

establish links with the Undercover Jigestablish links with the Undercover JigCaution: Drilling can meet the brinkCaution: Drilling can meet the brink

After each long or short boards were drilled left and right, they can be screwed and glued. To this end, they should lie flat on the bench and as safely secured to avoid slipping.

Danger: Also planed strips rarely have an exact consistent level. It may happen that the cut surfaces are uneven. In this case, it is advisable to align the inner edge and to put the offset completely to the outside. The meaning is in the later processing. The frame can be easily grind the outside than on the inside, because the interior angles can not be ground accurately. After reducing the offset is no longer visible.

Always align the inner edgeAlways align the inner edgeDifferences can then be ground downDifferences can then be ground down

Step 7 - insert cork mat and fix with angle

Angle keep the cork and stabilize the frameAngle keep the cork and stabilize the frame

A polished section provides a smooth surface and can disappear last paragraphs. Planed timber frames are very smooth and a particle size of 180 or 240 is therefor absolutely sufficient. If you like but can not roughly pregrind and create with grain 400 a perfectly smooth surface. To be subsequently oiled the surface - do not grind finer than 180 grain.

Then the angle as shown in the picture are used and fixed with screws 3.5 x 20th The angles keep the cork mat while ensuring better stability of the frame. In addition, the cork mat, as seen in the picture, are secured with additional screws and washers.

Then picture hook or other options are attached to the suspension. When the suspension in the desired location is a cross line laser beneficial. The larger the object to be suspended, the clearer an oblique positioning would be visible.

The cross line laser ensures perfect positioningThe cross line laser ensures perfect positioningBig enough for a lot of notesBig enough for a lot of notes

buy ready corkboard on Amazon.de