How to Make Barn Doors for Stage Lighting
- 1). Place an aluminum sheet on the work surface. Cut out two 7.5 square inch sheets with metal shears.
- 2). Mark two trapezoids on an aluminum sheet with these dimensions: 7.5 inches for the base, 9 inches for the top, and 7.5 inches for the height. Cut out the trapezoids with metal shears.
- 3). Sand the rough edges of the aluminum pieces with 600-grit sandpaper.
- 4). Spray paint the aluminum pieces with black high-temperature grill paint. Allow the paint to dry fully according to the manufacturer's instructions.
- 5). Screw one side of a self-closing cabinet hinge into a side of a theater lighting gel frame using a power drill and driver bit with 2 #6-32 3/8-inch screws. Repeat this process on all four sides of the gel frame.
- 6). Screw the opposite side of one hinge into the center of the edge of one of the 7.5-inch square pieces using a power drill and driver bit with #6-32 3/8-inch screws. Repeat this process with the remaining 7.5-inch square piece on the opposite side of the gel frame.
- 7). Hold the middle of the 7.5-inch edge of one of the trapezoidal pieces over one of the free hinges and screw it in place with a power drill and driver bit using 2 #6-32 3/8-inch screws. Repeat this process with the remaining trapezoidal piece on the remaining free hinge.
- 8). Spray paint any unpainted areas of the barn doors and allow the paint to dry fully according to the manufacturer's instructions.
- 9). Swing each hinge through its full range of movement to check that they are flexible.
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