Alfresco feature ceiling panelling

Nailbag

Australia and New Zealand's Best D.I.Y. Project 2024 entry See more

A friend of mine wanted a ceiling for his Alfresco area to finish and hide the rood frame. I saw these new wall panels at Bunnings and it gave me an idea...

Materials

Tools

Prempanel 2700 x 600 Oak Acoustic Panels

90mm x 35mm M10 pine

Otter 50mm 14G black button head screws

Batten Screws 75mm x 14ga

Custom U-channel flashing

Tape measure

Drill & 2mm pilot bit

Impact driver

Circular saw with 40tct blade

String line

Steps

123456

Step 1

1/6

Step 1: Measure and mark out the centre line of 2700mm x 600mm within the roof space. Using a string line helps with this.

Next Step

Step 2

2/6

Step 2: Cut and fix the 90 x 35 pine as battens to the existing roof frame to that the feature panels will fit half-way on each batten. This allows for the next panel to the side or end can be fixed. I used a frame cut but you could use 75mm batten screws through pore-drilled 6mm holes

Previous StepNext Step

Step 3

3/6

Step 3: I used off-cut of the pine and made offset blocks that I clamped to the battens. These were used to support the panels while they were being fixed in place by the black button head screws.

The black spacing between the timber panels is actually a sound-check material that compresses. so screws can easily be over-driven, hence using flat button heads. When driving the screws, you need to use your fingers to hold open wider the timber slats so the button heads can clear the edges and stop damage.

The panels are very flexible so having a platform ladder and a step ladder with two people are required, though I did manage to do this on my own. Not my first choice!

Previous StepNext Step

Step 4

4/6

Step 4: There will be cutting required, both end and by length. The straight edge clamped to the cutting line and a fine toothed blade was used on a circular saw. Taping the cutting line with blue painters tape will reduce any splintering. This was performed on a couple of saw horses.

Previous StepNext Step

Step 5

5/6

Step 5: as this product is internal and I had the edges of the panels exposed to the weather, I had made up at the local plumbing supplies 26mm (ID) x 15mm U shaped colourbond Chanel that I trimmed and fitted to all edges wand fixed with silicone.

Previous StepNext Step

Step 6

6/6

Step 6: I installed solar LED string lights (not seen in the photos) through every 2nd black Channel.

Previous Step

MitchellMc

Well, that is certainly the bee's knees @Nailbag! I love that. Such a sleek look that adds interest to the space yet isn't over the top.

I'm sure your friend was very impressed with the results.

Well done, and many thanks for sharing.

Mitchell

Nailbag

Thanks very much mate and yes he was. But now has started a list of other projects for me 😩

JacobZ

Sounds like you're suffering from success there @Nailbag.

Congratulations on the project.

Jacob

Nailbag

Haha thanks very much Jacob

minklet

Looks fantastic @Nailbag. May I ask how they're holding up? I want to do something similar, particularly for the acoustic qualities of reducing reverberation, but I would have assumed these things would soak up moisture?

Nailbag

Hi @minklet

I was there a few weeks back and are actually doing very well with no signs of swelling which was my main concern. The flashing I had made up which was very difficult to install plus additional silicone appears to be doing the job. I used a "U" channel on all ends. It's really important to install as many flat headed screws within the recessed black material as the panels aren't made to sustain. their own weight. And they are definitely not intended for outdoor environments.

My son installed the panels on his TV wall mainly for aesthetics, but it actually has deadened the room noticeably as the floor covering is timber.

Nailbag

minklet

Great info, thanks very much