Test set up 2 months before the event. |
The canopy was 1/2 Oval with solid walls and a spoked
ceiling. At the widest it was 70-feet. It had a depth of 40-feet from the
center pole to the back and middle of the oval.
The center pole was a heavy duty light pole and was probably the most important part of the structure.
The canopy is made from pipe and rail. Pipe and rail is
nothing more than EMT electrical conduit (in our case 1" found fairly
inexpensively at Home Depot or Lowes) and canopy fittings (generally found at
army surplus and camping stores or can be ordered online from many places
including www.gvtoolsandtarps.com).
To get the curve, Bob made custom canopy fittings to match
the angles needed. Most standard canopy fittings come in only 90°, 180° and
45°.
The custom fittings were made from a slightly larger diameter chain link fence
pipe (also found at Home Depot or Lowes). He cut, bent and welded it together.
The 7-foot uprights and 10-foot horizontal pieces were EMT
electrical conduit. The "feet" of each upright was a 3-foot EMT
hooked to the upright with a 4 way edge fitting (You can see a picture of this
fitting at www.gvtoolsandtarps.com. Look under "1-inch fittings for flat
top canopy"). Sandbags were placed on each foot. You can call your local
fire department and they will lend you the sand and the sandbags. You will
supply the shovels and sweat.
The fabric was purchased at SAS Fabrics 1111 East Indian
School Road 85014 (there are also SAS Fabrics in Tempe and the west valley). The fabric ended
up being about $1 a linear yard if I remember right. It was 108" wide
which was perfect for what we needed it for. We purchased 138 yards of the
fabric.
We cut one long piece of fabric to follow the wall and
attached it at the top rails with PVC clips. These clips were made from 1"
thin walled (200 PSI) PVC pipe. The thin walled part is important because the inner
diameter must be large enough to clip over the 1" EMT. The PVC pipe was
cut into 4-inch to 6-inch pieces. He then created a C shape from the PVC pipe
by making to cuts to the length. You might want to sand these edges so they
don't cut into the fabric when you clip it to the pipe.
Because the fabric was shear we used additional fabric at
each upright, gathered and hanging vertically.
The fabric ceilings spokes were fastened to the walls the
same way and then gathered to the center pole. They were fastened to the pole
with metal macrame rings (Joanns Fabrics and Crafts) and quick links (Home
Depot) . The fabric was attached the macrame rings by running the end of the
fabric through the ring and zip tying it to itself. The pole was dark green so we covered it up by making bishop's sleeves with the fabric down the entire length. No sewing was involved. We just loosely wrapped the fabric around the pole at the top and then, in intervals, zip tied it around the pole leaving poofs of fabric hanging to cover up where we had gathered it with the zip ties. At the bottom we just let it puddle. We hid that crazy looking
mess where the ceiling spokes came together with the tissue paper flowers we made and hung around the reception area.
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