Calculate the sizes of the baffles and gobos you want for your studio. Common sizes are 2-by-2-feet for wall-mounted panels and 2-by-4-feet or 4-by-4-feet for free-standing gobos. Baffles can be made in any size to fit your needs. For illustration, we will consider a 2-foot square wall panel and a 2-by-4-foot gobo.
Cut four pieces of 1-by-6-inch lumber to 22.5 inches for the top and bottom of both baffles. Cut two pieces of 1-by-6-inch lumber to 24-inch lengths for the sides of the wall panel. Cut two pieces of 1-by-6-inch lumber to 48 inches for the sides of the gobo. Cut one piece of 1-by-8-inch lumber to 26 inches for the base support for the gobo.
Construct the box frames using the 1-by-6-inch pieces. Top and bottom boards go between the side boards in both cases. Use 2-by-2-inch bracing strips inside each corner, and fasten each board to the bracing strips with four or more 2-inch drywall screws evenly spaced along the 6-inch ends.
Fill the box frames with mineral insulation. Cover the insulation with open-weave fabric, such as burlap, stapled to the frame. Start at one end, and pull the fabric tightly and evenly as you go. The gobo requires fabric on both sides, while the wall panel can be covered on one side only.
Cut away excess material and cover the staples with trim molding. Center the gobo on the 1-by-8-inch board, with a 1-inch overhang on each side. Fasten the base using 2-inch drywall screws. Hang baffle panels on the wall with angle brackets.