Fine Dining - Tin Punch Screen

Ceiling tiles with the look of tin bring elegance to this simple project.

Project #Nov061

Tin Punch Screen

A wide variety of tiles are available at Lowe's — choose from paintable surfaces as well as an assortment of beautiful colors and finishes.

General Instructions

The overall dimensions of this project are 84 1/4 inches wide and 83 inches high. Cut and label the parts as needed, using the Cut List as a guide and adjusting for fit.

  1. Build the panel assemblies.
    • Cut the stiles, rails, and bottom rails per the Cut List.
    • On a stile, form the decorative feet by marking 1 inch in from one edge, and then mark 3 inches up from the bottom of the opposite edge, as shown. Place a flexible metal ruler between the two points to form a curve. Mark the curve, and cut it. Use this stile as a pattern for marking and cutting the others.
    • Place each uppermost rail flush with the end of each stile. Space the other rails 23 inches apart. Tip: On the backs of the stiles, mark 1/2 inch from the inner edges of the openings to keep that area clear of pocket holes. Attach the rails and the bottom rails to the stiles as shown in the illustration, using glue and pocket hole screws.
  2. Prepare the assemblies, and install the panels.
    • After the glue cures, use a router to cut a rabbet 7/16 inch deep and 1/2 inch wide around the inside edge of each assembly's opening. Remove the screws adjacent to the rabbet as you proceed, and replace the screws after you cut each rabbet. Square the corners of each rabbet with a chisel.
    • Insert a ceiling tile into each opening.
    • Cut the plywood panels. Insert a panel over each ceiling tile, and secure with wire brads.
  3. Finish the screen assemblies, and install the hinges.
    • Fill all holes with wood filler, and sand smooth.
    • Prime and then paint at least two coats on all wooden surfaces, and allow to dry.
    • Join the completed screen assemblies with the hinges. Between each assembly, attach a hinge 9 inches from the top, 9 inches from the bottom, and in the center. To make the screen fold as shown, alternate the locations of the hinges from front to back.
    • Predrill, and attach furniture glides to the decorative feet.
Illustration

Tin Punch Screen

Cut List
Part Material Size (in inches) Quantity
Rails (6-foot-long) 1 x 3 3/4 x 2 1/2 x 23 9
Stiles (8-foot-long) 1 x 3 3/4 x 2 1/2 x 83 6
Bottom Rails 1 x 4 3/4 x 3 1/2 x 23 3
Panels Plywood 1/4 x 23 7/8 x 23 7/8 9

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Project Details
Skillset: Intermediate
Rough Cost Estimate: 295*
Rough Time Estimate: 2 days
Tools You May Need:
  • Circular saw with a straightedge guide (or table saw)
  • Pocket hole system (K3MS Kreg Jig K3 Master System)
  • Router with 1/2-inch rabbeting bit
  • Chisel
  • Power sander (or sanding block with various-grit sandpaper)
  • Drill/Driver and bit set
  • Hammer with nail set (or pneumatic nail gun)
  • Clamps
  • Tape measure
  • Pencil
Shopping List

Lumber **

  • 3 (6-foot-long) 1 x 3s, poplar
  • 6 (8-foot-long) 1 x 3s, poplar
  • 1 (6-foot-long) 1 x 4, poplar
  • 1 (48- x 96-inch) sheet of 1/4-inch-thick birch plywood
  • 1 (48-inch-square) sheet of 1/4-inch-thick birch plywood

Materials and Hardware

  • 1 package (#18 x 5/8-inch) wire brads
  • 1 package (1 1/4-inch) Kreg pocket hole screws (fine thread)
  • 3 pairs (2-inch) non-removable pin hinges
  • 2 packages (3/4-inch-diameter) nail-on furniture glides
  • Moulding glue
  • Stainable wood filler
  • Paint (Valspar, La Fonda Deep Olive #6006-6C, satin)
  • 9 ceiling tiles (Classic Tin Style Ceiling, Traditional 2, Paintable White, Finish #00, special order)

* Does not include labor costs or applicable taxes, which vary by market, or the cost of tools.

** Availability/Selection varies by market.

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