Directions to Make a MirrorConstruction of a Mylar Mirror
Following are instructions for the construction of a mirror using reflective Mylar sheeting.
Materials used are: 2 MIL IS EASIER TO WORK WITH, 4 MIL IS MORE DURABLE.
- 2 MIL OR 4 MIL mil reflective Mylar plastic sheeting
- Steel track for drywall framing, 1 5/8 “, made by Bailey Metal Products
- Angle framing trim, 2”, Bailey Metal Products
- Aluminum rivets, 3/16”, or sheet metal screws
- Masking tape
- Aluminum foil tape, 2” wide
The steel track and angle used to make the frame:
Aluminum foil tape:
Cut four pieces of steel track according to the dimensions of your desired mirror. Note: the maximum dimensions are 2 inches less than the dimensions of your Mylar sheet.
Arrange them in a square with the open part of the track facing inward and the corners overlapping. Secure the corners with clamps and measure side to side in both directions to ensure that the sides are parallel.
Measure diagonally from corner to corner to ensure that the frame is square.
Secure each corner with a rivet.
Mark the middle of each side and cut a piece of angle trim to fit diagonally between each mark. You might have to cut a piece off the end of the angle to get the corner to fit inside the track.
Double check the squareness of the frame and then cut four pieces of angle trim and attach them inside the track using rivets.
Flip the frame over and insert a rivet into the other side of each corner.
The completed frame:
Lay the frame down with the angle trim on the top. Cut a piece of Mylar sheeting that will overhang the frame by 1” on all sides.
Cut a 1” square from each corner of the Mylar sheet.
Center the sheet on top of the frame. Secure the middle of one side of the sheet to the frame using a short piece of masking tape.
Go to the opposite side and secure the middle with masking tape stretching the sheet as tight as possible.
Do the same across the other two sides and then continue to add pieces of masking tape working evenly towards the corners. Pull the sheet as tight as possible with each piece of tape.
As you progress you should start to see a clear cross shaped section on the sheet.
When you have worked all the way out to the corners the sheet should be flat and tight.
Check that the tapes are all tight and there are no wrinkles in the sheet. Then cover the entire perimeter of the mirror with aluminum tape.
Two completed mirrors. They will be attached to the wall using angle brackets and sheet metal screw.
5 mil mirror