We no longer offer grille fabric installation or replacement services.
Tone chamber covers are taken for granted by most people. However, they have the last effect on the soundwaves emanating from the chambers before reaching our ears (ignoring room acoustics). The materials and weaving pattern must be visually appealing, and acoustically as transparent as possible, while still providing an opaque covering to hide the speakers or pipes.
Acoustical transparency is important for minimizing sound spectrum loss. Older materials were heavier and densely woven. Heavier materials tend to sag over the years. A denser weave will "muffle" the sound by attenuating the higher frequencies (shorter wavelengths). In extreme cases, this imbalance causes the lower frequencies to overpower the brighter sounds, creating the overall perception of dullness, heaviness, or a muddiness. As many years pass by, dust (coal dust in old designs!) clogs the tiny openings, contributing to the overall attenuation of sound quality and loudness.
The material I use is made by Acoustone Corporation - (718)782-7367. It is actually a woven vinyl-coated fiberglass material. It is extremely stable, and will not shrink or expand when exposed to changes in room temperature or humidity. It is suitable for exterior, as well as interior, applications, and can be painted. It is approved by the California State Fire Marshall for meeting the minimum requirements of flame resistance.
Below are photos of a grille cloth replacement job at Beaver Creek Cumberland Presbyterian Church in the Powell area of Knoxville, Tennessee. Two of my sons, Jeremy and Jonathan, are my assistants. The color of the new material matches the surrounding surfaces almost exactly, even though it doesn't appear this way in some of the pictures. And even though the material appears solid in the pictures, it has a lovely raised diamond pattern in the weave. Especially note the water damage, discoloration, and sagging with the old material. The new material will never look like that, because it can't be affected by those same conditions!
Installation technique is very important. The material must be taut and square when stapled. The pattern must be straight all the way across, both horizontally and vertically (meaning the tension on the material between any two stapled points must be the same). Uneven tension will result in a wavy pattern! Each of the 52 pieces of molding was tagged by its location and orientation, due to varying individual dimensions.
Assistants are sons, Jeremy on left, and Jonathan on right.
New grille covers match the existing wood finish almost perfectly.