$30 DIY Flag

T

tcindie

Well-known member
I apologize in advance, this is not quite as detailed as my c-stand how-to...

Bill of materials:

Hardware/home improvement shopping list
(3) 1/2" Barb Elbow (these came in packs of two. They're brass connectors that would fit inside flexible rubber pipe.
(1) 3/4" x 1/2" x 1/2" Barb Tee
(1) 1/4" nipple pipe
(1) 3/8" 10' threaded rod

Fabric/Craft Store shopping list
(1) Blackout Cloth, 1 yd @ 54" wide
(1) Black Craft Felt, 2.25 yd @ 72" wide
(1) 1" x 3' self adhesive velcro
(1) Black thread if needed.


Tools Required:

Hack saw or bolt cutter
Hammer
Scissors
Sewing Machine

Ok, this first half is pretty straight forward. First we need to cut the four sides of the frame from the threaded 3/8" rod. We'll be doing a 18" x 36" flag, and the sides need to be cut 2" shorter than the target outer dimensions of the flag. So in this case, two 16" long pieces, and two 34" long pieces.

Now we coax the cut rod pieces into the elbows, it likely will take a hammer and some doing to get them to go in. Remember on the Tee joint it should be threaded rod going in the bottom and side, with the 1/4" nipple pipe should be coming out the top.



Once all the rods are in place it will look like this:

 
Now in the house for the sewing portion
(note: I don't recommend doing this tired... I spent 3 hours on it because I sewed a couple seams at the wrong time making it impossible to turn inside out.)

Ok, first off, here's what we are working with...



We need to fold the felt so that the seam is running down the full length of the 72" side.

Next, lay out the blackout cloth on top of that...


Once it's all nicely positioned and what not, sew up the bottom seam. Oh, you'll also need to cut the felt along the fold so that it's two long pieces.

After sewing the bottom edge, turn it inside out so the blackout cloth is sandwiched between the two pieces of felt.
 
You will have to work out the sewing part on your own, because I couldn't take pictures while sewing...

Basically you just want to fold the edge over, and sew it back to itself, then cut the excess off. I left about a half inch seam around the sides below the frame, and inside the frame just got the pressure foot to run along as close to the bar as possible. Inside the frame I also went over each length twice with straight stiches and twice with diagonal stiches.

Add a couple pieces of velcro, and what you get is this:

36" x 18"



36" x 36"



54" x 36"

(The weird bright streak on the 36x54 is the velcro reflecting from my cameras flash)

And does it work you ask?

Why yes, indeed it does:

Total black out.

My Total Build cost: $36

It is not fire retardant, so if you build one and plan to use it close to hot lights I'd recommend treating it with a flame retardant chemical. Here are a couple links for that:
http://www.natfire.com/
http://www.fire-retardant.biz/


Note: you may have better results with sewn on velcro, not sure how well the self-stick velcro does, and iron on probably isn't an option because the blackout cloth may disagree with the hot iron -- it's a little rubbery.
 
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