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Step 4Construct
I'm not going to go into an exhaustive explanation of my entire build process - it will vary a great deal depending on the design of your wall and the location you decide to put it. And a project like this shouldn't be attempted without basic construction knowledge. However there are a few important things.
First anything load bearing should be bolted - not screwed or nailed. In the pictures you can see that the 2 x 6 joists are attached to a 2 x 4, there is a bolt doing down through the top of the 2 x 4 into the 2 x6 then the 2 x 4 is bolted to the ceiling. Nails come loose with vibration, screws tend to snap. Anything load bearing gets bolts. No exceptions. (well of course the plywood is screwed onto the frame but I'm talking about when constructing the frame)
After constructing the frame it was time to prepare the plywood for attaching to the wall. The general rule for t-nuts is 72 per sheet of plywood. This means that there is a rectangular pattern of one t-nut every 8 inches in both directions. I marked the plywood using a chalk line then drilled the hole where the two lines intersect. Here is some more information about this process. (Morganic has very good hold prices, I bought a number of my holds from them)
http://www.morganicclimbing.com/Help/TNuts.htm
When you drill the holes for the t-nuts drill from the side that is going to be facing outward that way any splinters wont be seen. I find it easiest to do one sheet at a time
1. Drill holes
2. Flip over
3. Set aside and do next sheet.
You don't want to hammer the t-nuts in just yet because you'll probably be cutting the plywood and not only will a t-nut ruin a saw blade but theres no need to waste t-nuts on waste parts of the plywood that won't be used.
You could probably use a piece that was already drilled as drilling template.
The next step is to mount the plywood
First anything load bearing should be bolted - not screwed or nailed. In the pictures you can see that the 2 x 6 joists are attached to a 2 x 4, there is a bolt doing down through the top of the 2 x 4 into the 2 x6 then the 2 x 4 is bolted to the ceiling. Nails come loose with vibration, screws tend to snap. Anything load bearing gets bolts. No exceptions. (well of course the plywood is screwed onto the frame but I'm talking about when constructing the frame)
After constructing the frame it was time to prepare the plywood for attaching to the wall. The general rule for t-nuts is 72 per sheet of plywood. This means that there is a rectangular pattern of one t-nut every 8 inches in both directions. I marked the plywood using a chalk line then drilled the hole where the two lines intersect. Here is some more information about this process. (Morganic has very good hold prices, I bought a number of my holds from them)
http://www.morganicclimbing.com/Help/TNuts.htm
When you drill the holes for the t-nuts drill from the side that is going to be facing outward that way any splinters wont be seen. I find it easiest to do one sheet at a time
1. Drill holes
2. Flip over
3. Set aside and do next sheet.
You don't want to hammer the t-nuts in just yet because you'll probably be cutting the plywood and not only will a t-nut ruin a saw blade but theres no need to waste t-nuts on waste parts of the plywood that won't be used.
You could probably use a piece that was already drilled as drilling template.
The next step is to mount the plywood
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