How to build and install a magnetic chalkboard for my toddler?

[emilybeck]

I want to build a solid magnetic chalkboard/blackboard for my toddler using some sort of metal sheet. I want to install it on the living room wall so we can use it for years to come so I want it to look good and last! The space is about 1200 x 1200. I've done some research and I've looked around in store - I'm imagining something like the attached picture. The questions I have at the moment are:

(1) I think this is the best sheet metal to use - Australian Handyman Supplies 1200 x 600 x 0.55mm Galvabond Mini Sheet - but I can't see anything bigger. Are there bigger sheets? If I used two of these, would I be stuck with a problematic gap down the middle of the board?

(2) Should I attach the metal to plywood or something before mounting on the wall? And (a) how do I size/cut the plywood (b) how do I attach the sheet of metal to the plywood?

(3) What can I use to make a frame to attach over the metal sheet? And how to attach?

(4) How will the finished product best be installed on the wall? My walls are masonry - I've got a masonry drill that I'm familiar with using. I'm not sure if cutting holes in the sheet metal will involve anything more specialised...?

Open to any advice or tips about anything that I have overlooked!! Thanks so much in advance!

 Magnetic chalkboard for kids

[EricL]

Hello @emilybeck 

Welcome to the Bunnings Workshop community. It's sensational to have you join us, and thanks for sharing your question about building a magnetic chalkboard for your toddler.

I suggest the following materials:

• CUSTOMwood 12 x 1200 x 600mm DIY Raw MDF E0 (x2)
   
• Australian Handyman Supplies 1200 x 600 x 0.75mm Galvabond Mini Sheet (x2)
   
• 42 x 19mm 1.2m DAR Pine Standard (x5)
   
• Dulux Design Black Chalkboard Paint
   
• White Knight Rust Guard Medium Grey Metal Primer Paint - 1L
   
• Ramset 8 x 50mm Universal Anchor - 20 Pack
   
• Zenith 8G x 30mm Countersunk Rib Head Chipboard Screws
   
• Parfix 300g Clear All Purpose Silicone (x1)

The general assembly instructions are to place the MDF panels on the floor side by side. Wash the Galvabond sheets in soap and water to remove oil and grease. Let it dry off, then prime surface with metal primer. Let the primer cure before putting on the Dulux chalkboard paint. Use the silicone to fix the Galvabond to the MDF panel. Place the 42x19 pine trim around the frame and trim where necessary. 

The center trim piece is to prevent your toddler from getting cut by the Galvabond. Drill pilot holes through the timber trim and steel, then use the 8g x30 chipboard screws to join the assembly together. Drill more pilot holes for the Ramset mounting screws mark its position on the wall and drill holes for the wall plugs and install the chalkboard with a minimum of two screws per side and two in the middle. You may adjust the number of screws to hold the timber trim piece in place along with the mounting screws.  

If you have any other questions we can help with, please let us know.

Eric

[emilybeck]

Hi Eric 

Thank you so much for this helpful reply and for the diagram. I was actually able to find a 1200 x 1200 sheet of steel which has made the whole thing much more straightforward. Today I took the first few steps, cleaning and priming the steel in advance of painting - and I've already run into a problem - well, a question at least! I used a small roller for the primer and now that it's totally dry (6/7 hours), the surface feels a bit rough to touch in some spots. I think there are patches where the primer is not totally smooth (it seemed to dry really quickly before I could roll it smooth) - but I also used a cheap small roller and I think some fluff from the paint roller has dried in the primer - is that likely? I'm embarrassed at how much of a novice I am in asking these questions!!

I guess the question is - how big of a deal are these rough patches? How smooth does the primer need to be in a project like this?

I applied a decent coat - if I clean the surface now, that might get some of the fibres - could I then sand down the uneven areas to prep for the chalkboard paint? 

Otherwise, if these issues are going to create problems for the final finish, then maybe I should just turn the sheet over and start from scratch again. And it would be great if you could tell me how to avoid the same mistakes!

[EricL]

Hello @emilybeck 

The rough spots are not a big deal, I suggest getting some 240grit sandpaper and lightly rubbing it over the rough spots, make sure not to sand away the primer. Your goal is to give the rough spots of the surface a light sand in order to have a smooth surface. Wipe the surface down with a damp cloth to remove all the sanding dust before you apply the chalk paint. I suggest investing in a more premium roller and make sure to wash the surface of the roller in water to remove all the fluff.

Squeeze the roller in a tea towel to remove all the remaining water in the roller. It's ok to use it damp, make sure to soak the roller in paint and then remove the excess paint by rolling it in the trays flat surface. Apply in straight lines and work diligently, do not runover previously painted spots you can fix errors on the second coat.

If you need further assistance, please let us know.

Eric