Method for making framed structures

A method for making a rigid irregularly shaped metal frame and attaching a flexible sheet of material thereto, said method comprising the steps of:

• (a) forming a planar pattern with a desired irregular peripheral configuration;
• (b) sizing an elongated metal channel so that its length is equal to the peripheral dimension of said pattern, said metal channel having a groove extending along one of its longitudinal surfaces;
• (c) heating said channel at predetermined locations along the length thereof;
• (d) pressing said metal channel into demountable conformity with the irregular periphery of said pattern to bring the opposite ends of said channel into abutting engagement with each other and to form the groove of said metal channel into an endless groove which faces outwardly of said pattern:
• (e) interconnecting the opposite ends of said metal channel to form a rigid endless metal frame of irregular configuration:
• (f) removing said rigid endless metal frame from its position of conforming with the periphery of said pattern;
• (g) placing a sheet of flexible material on a holding fixture which is provided with means for demountably gripping the edges of said sheet so that it is held in a stretched planar attitude:
• (h) supporting said holding fixture on a support surface so that said sheet is in spaced parallel relationship with said supporting surface;
• (i) placing said rigid endless metal frame in juxtaposed bearing engagement with one of the planar surfaces of said sheet of flexible material held in said holding fixture;
• (j) exerting a force on said endless metal frame to holdingly deflect said sheet into contiguous engagement with said support surface to draw said sheet taut;
• (k) releasing the edges of said sheet from said holding fixture;
• (l) inserting the edges of said flexible sheet of material in the endless groove of said rigid endless metal frame;
• and
• (m) wedging an elongated spline into the endless groove of said rigid metal frame atop the edges of said flexible sheet of material, said spline having means which form an interference fit with the endless groove of said rigid metal frame upon insertion therein.