Well, it took some doing, but now it’s done. The new CBR Studios NJ video production studio has been operational for a few weeks now, but transforming it from an empty room to a massive green/white cyc wall was no simple task. This blog entry will give you some insight as to how we designed, constructed and completed the new cyc wall at CBR Studios in Woodland Park, NJ.
First and foremost, you need to decide how big you want your cyc to be. For us, it was imperative that we could fit large subjects such as cars, SUVs or even a boat? We had to add the ability to support heavy duty equipment/products and sizable groups of people. We moved into our 4,000 sqft warehouse that was formerly a boxing gym and began the demolition.
Once the area was cleared out and ready for construction, we gathered the necessary materials which consisted of: 1″ plywood, 1/8″ masonite, drywall and steel framing. We began by framing out the 2 walls and installing the drywall. Next we began cutting the plywood to the size we wanted our curve to be. We decided on 30″ high on the wall and 30″ out on the floor. We drew a curve on the pieces of plywood and cut them out using a jig saw. We installed them to the wall by screwing 1×1’s in the studs on the side of the curves. To reinforce the structure, we added 1×4’s and 2×4’s between them, strengthening the cyc wall curve. We did have some issues with non level floors so we had to improvise and remove part of the curve support and add alternate support. The trickiest part of building the cyc was the corner where the 2 walls met. We added 3 supports to build a custom bowl shape where the masonite would be fastened for future plaster work (see picture).
Once the curves were installed, we used a nail gun, staple gun and heavy duty adhesive to attach masonite to the curve. We sunk screws into the top across the wall, the plywood curves and the reinforcement beams between them. This creates the infinity wall look. The corner is by far the trickiest part of the whole process. We used a piece of cardboard over the corner area and traced the shape when it was covering the open area. Then we cut the masonite in 9 pieces to allow it to take its shape. It kind of resembled a shield or bowl.
The curves are done! Time to move on to the plaster and spackle! We did not attempt this on our own. We hired a local painting company who handled the 1 task: SEAMLESS!!!! It came out fantastic!
Once the curves were finalized, we primed the entire cyc and all walls. We were very happy with the results and also began to prime the floors getting ready for paint.
We installed our truss system with hoists, finished the painting and we were ready to shoot!