Building the VuePod Frames

Figure 1: The Final Product

The VuePod needed 4 steel frames to support the 12-55” 3D TV’s.  One of the main purposes of the VuePod was to build a low-cost immersive visualization system.  Keeping this purpose in mind it was decided to hire a student that would be able to weld and build the frames.  4 frames were required, with 3 TV’s mounted to each frame.    

Each frame required:

• 75’ of 1” square steel tubing 1/16” thick
• 10’ of perforated steel angle
• 4’ of perforated steel 
• 12 - 2 ½” x ⁹/₁₆”  Steel Bolts  
• 18 - 1 ½” x ⁹/₁₆”  Steel Bolts
• 8 - 1” x ⁷/₁₆”  Steel Bolts
• 2 - 25 lb Concrete blocks
• 3 - Rocketfish - Low-Profile Tilting Wall Mount for Most 32" to 70" Flat-Panel TV's - Black

The first step was to cut the steel using a gravity fed band saw.  Certain pieces required holes to connect to the perforated steel angle and other steel pieces.  A drill press was used to drill the holes.  After cutting all of the pieces and drilling the holes, a MIG welder was used to build the frames.  Figure 2 shows a typical weld. Figure 3 shows the completed welded frame. 

Figure 2: Weld

Figure 3: Welded Frame

After welding, the different pieces were assembled to accommodate the desired height and angle for the TV’s as shown in Figure 4.  It was important that the TV’s matched and lined up properly. 

Figure 4: Arm Component

Lastly, the 3 mounts were bolted to the frames using the 1” x ⁷/₁₆” steel bolts.  Figure 5 shows the how the center TV was mounted to the frame.  

Figure 5: Center TV Attachment

Then the TV’s were placed on the mounts. Figure 6 shows the lined up TV’s, and although not perfect, when the TV’s are on and lights are off it is difficult to notice the lack of perfection. 

 

Figure 6: Individual Frame with Mounted TV's

The concrete blocks were poured and given time cure before they were placed on the mounts.  The concrete blocks were used as counter weights to keep the TV’s from falling forward.  Figure 7 shows a concrete block.  The frames were designed as such to be able to support themselves, but the blocks add extra safety and security.

Figure 7: Concrete Block

Figure 1 shows the final frames and their layout.  Figure 8 shows a hand drawn sketch that was used to build the frames.  Safety precautions were taken throughout the process and proper PPE was worn.

Figure 8: Hand Drawn Sketch of a Frame

For questions, please comment with contact information.