Need some help for the inside corners of EMT sim enclosure

[sbierlink08]

Hello to all the smartypants!

First of all, I really appreciate this site and all it's done for my ability to get ideas from you all. There are so many great builds. This is my first post because I've run into a tough spot that I can't find a solution for...

My black cloth is the 9'10" double nap commando cloth from Chicago Canvas (as recommended by gunghogolf.com). I used the circo 3/4in tarp clips (for 1" conduit, got them at a1tarps.com and amazon) to secure everything with good tension on all sides. I did not want to use pipe insulation here because of the inability to get nice tension on the cloth in all directions.

The problem comes from the idea that at some point, a stray ball will inevitably strike just at the right point that it will either bounce straight back, or land just outside of that and possibly tear the fabric.

I ordered some 4" thick upholstery foam sheets that I can cut into any dimension I need, so I assumed a right triangle for the corners would be best. I then assumed I'd cover the foam in black cloth and sew it up in the 90 degree corner so it would be hidden once attached.

So the issue really is: how to use foam in all these corners that will prevent the potential issues, and, how to attach a cloth covered foam piece to the commando cloth in such a way that it won't sag, and won't create stress on the commando cloth over time to potentially create tears.

I think 3M super 77 would be a good adhesive to use for this, but again, I'm not sure if the weight of a vertical piece of foam would at some point create sagging on the sides of the commando cloth.

I don't love the idea of sewing it because of the time involved, and the difficulty in getting it done cleanly since I'm certainly no seamstress.

I would appreciate any input you guys have on what the next steps should be.

[FierceVibe]

I know Carl's Place sells memory foam by the foot to place on the conduit that frames the impact screen. They sell it for $7.50/ft. I'm in the process of working up a golf simulator and asked on this forum about what people thought about it, and they liked it. Maybe you could contact Carl's and see about getting whatever fabric cover they use to hold the foam in place.

[sbierlink08]

FierceVibe I did contact them. They were certainly willing to help, but after seeing the same pictures I posted, they said none of the foam parts or pieces they sell would work very well for this application. They added as well that they don't make anything to attach them, whether it be adhesive or sewn. I imagine their kits probably have a different process for assembly that makes it covered beforehand so it's not an issue.

Thanks for the input though. I'm still leaning towards my idea, but I just don't know how it will work out, and re-doing something a few years down the road may not be crazy expensive, but it's a ton of work that I'd prefer to avoid.

[GullLakeMi]

I contacted Carl's (who I bought a premium screen from) and they said they would only sell the foam as part of an enclosure kit. Probably worth double checking yourself if you want it bad enough.

[tntfox]

I made my own. I bought a piece of foam rubber and an electric knife to cut it (works great). I covered the foam slabs with awning material. Instead of sewing the material around the foam, I took an easy route and used zip ties every 12 inches to "stitch" the fabric around the foam. I also mitered the corners so they fit like a picture frame. They dont have to be perfect as they are black and blend in to the frame. In my enclosure, the protectors do not stop every ball from making it past, but if a ball hits the EMT, the protector keeps it from coming back out. To protect against balls passing both the protector and the pipe and hitting the wall, I hung moving blankets around the back corners and they have proven to be very effective at knocking down a ball.

If you zoom in on the picture below, you can see the horizontal and vertical protectors I made.