Aaron's Booth Project

Aaron is a craftsman that regularly posts on our BBS and has taken the time to document how he built his spray booth and is generous enough to share his experience with us.  Below are his pictures and comments.

(click on pictures to enlarge)

The beginning of a long project.   If I only knew what I was getting into!!

After a $300, diamond blade, lots of water, and lots of jackhammering, I have a 40" deep,  60"wide, 18' long hole in the floor!

Being environmentally conscious as I am I decided to line the whole pit with duct work using the duct as my forms to pour my cement in. In doing this the pit will always be sealed, or at least until the galv duct rusts through( after I'm dead) so there is no way for the trapped overspray residue to mix with ground water and contaminate the soil. Unlike concrete pits that leak between the wall and floor. And the sheet metal is much easier to clean. I just coat it with peelable coating and peel it if when it becomes soiled just like the walls in the booth. Notice the steel I beams this is to hold the floor up in the "T" section of the pit where the cement is poured over top of the tunnel. These I beams are coved over with more tin and concrete poured over them. The ends of the beams stick in the walls to support them sort of like a beam pocket in your basement wall, only there holding concrete up not wood.

This is another shot of the duct work I fabricated for the pit.   Lots of welding!!!

The pit now ready to pour cement. Notice those I beams now have tin ontop of them, to hold the cement. And the wire mesh on top.

A good view of the tunnel, before cement.   Notice the angle iron, that is where the booth wall will sit.

Fresh cement !!!!! I thought I'd never finish welding that 18 gauge
duct work together!

The walls are going up. Basically they were just sheets of 18ga sheet metal with 90's bent in them, I ordered them like this from my supplier, then I cut out for the lights, drilled my bolt holes etc....

This photo gives U a good idea what the pit looks like after the cement is poured. In case your wondering what that black pipe is above the booth, it is my airline.   I have 2" air line in the shop..

  I built all the explosion proof fixtures also. They were built out of 2x2x1/8 angle. Then I welded 1/2"x1/4" strips on top of the angle to hold in the tempered glass.   I built 1" wide frames to keep the glass from falling out. The strips are taped, and bolts go through the frame.   I have urethane gasket between the glass and the frames.

I painted the frames rattle can white (Leroy would be proud).  The rest of the booth is white peelable coating.

 Now these are fans!!

This is the outside of the booth.  Notice I built metal boxes the cover the lights


This is the intake and exhaust plenum.  The exhaust duct doubles as an exhaust fan for the shop. If you notice in the picture the whole front of the plenum is a door, that can be opened, to ventilate the shop area. On the right of the exhaust plenum is an intake plenum, that houses the prefilters in the colder weather I can put my reddy heater in front of this to heat the air entering the booth. I have also used it to force dry the paint. I can get it up to 140 degrees in the booth, by opening the damper (DOOR) I have installed between the exhaust side and the intake side. I shoot the heater toward those filters on the outside, just like I would normally when its cold, but I leave the exhaust fan off, and only run the intake fan. The air just recirculates between the 2 plenums but the fan still has enough draw to draw in heat from the heater, even though the heater is not in the air stream when I'm operating the system this way, Because as I said , I'm recirculating the air, because of the door I have open connecting the 2 plenums.......


Back View
(looking into the booth)


(looking out of the booth)

 This is a picture of the inside of the booth looking out.  That is diffusion media installed in the ceiling.   Notice the glass overhead door.  The section of ceiling directly above the door is on piano hinges, and opens up to allow the door to go up inside the ceiling when I'm loading or unloading a vehicle into the booth.

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