Here are the details of how I built my 4:3
screen for use with my Sony 1292 CRT Projector. I did it
in 2 parts, the screen frame and then the screen itself.
DIY Projection screens are really very easy to make.
The size of the screen is 105" x 79" (2625mm x 1975mm).
This gives me a 4:3 screen with a diagonal of 132" (3300mm)
and a 16:9 screen with a diagonal of 120" (3000mm).
I chose to go with a 4:3 screen as I watch about 30% of
4:3 and 70% of 16:9 source. With this screen I can utilise
the maximum area of the raster for 4:3 material without
the potential for burn-in or wear within the 16:9 image
Here for a guide to stretching canvas that I used when
stretching the blockout material over the frame.
Here is the completed screen frame. I used 90mm x 35mm Treated Pine timber for the whole frame and the corner supports.
I also used 100mm metal angle pieces for the corner supports with 40mm wood screws and straight metal pieces also with
40mm wood screws for the upright centre support.
(Click on the Thumbnail for a larger version - 110KB)
Here is a shot of the metal angle bracket and the timber corner support I made. It holds the whole frame very rigid
which helps to keep the screen material nice and taught.
(Click on the Thumbnail for a larger version - 96KB)
Here is a shot of the straight metal bracket and the timber upright centre support I made. It also helps holds the whole frame very rigid and square.
(Click on the Thumbnail for a larger version - 121KB)
Here is a shot of the 3-Pass blockout material that I am using for the screen. It has a cotton side and a rubbery side. When I ironed the material on the
cotton side (1.5 hours of work!) I noticed a lot of marks that would not come out so I decided to use the rubbery side to project onto. Notice the helper assessing the border of the material for uniformity.
(Click on the Thumbnail for a larger version - 120KB)
Here is the frame positioned on top of the material, ensure that it is in the middle.
(Click on the Thumbnail for a larger version - 117KB)
I folded the corners of the screen
over each other and cut off the excess material to make it
look a bit neater. You can also see how I stapled the material
to the frame. The DIY projector screen is coming along!
(Click on the Thumbnail for a larger version - 156KB)
Well here it is!! A MASSIVE screen for my massive Sony 1292. I will be attaching it to the wall with right-angle brackets which will attach
to the inside of the frame and protrude out the sides of the frame. These will then be screwed to the upright studs in the wall.
(Click on the Thumbnail for a larger version - 81KB)
Here is another shot of the completed screen (along with my other helper).
(Click on the Thumbnail for a larger version - 105KB)
Here is a list of the materials that I used:
x2 70mm x 35mm Treated Pine lenghts @ 2485mm each
x2 70mm x 35mm Treated Pine lengths @ 1975mm each
x1 70mm x 35mm Treated Pine lengths @ 1835mm each (centre support)
x4 70mm x 35mm Treated Pine lengths @ 700mm each (corner bracing)
x4 Right-Angle metal reinforcing straps
x2 Straight metal reinforcing straps
x24 40mm Wood Screws
x8 60mm Wood Screws
x1 2400mm x 3000mm 3-Pass Blockout Material - Purchased From Lincraft, Australia
xLots of Staples
Here is the time taken to build each stage:
Frame: 3 hours
Screen Fitting: 1 hour
Hanging my new screen: TBA
Watching movies on my home-made screen: Forever!
The cost of this project was:
Frame: $45.00 AUD
Screen Material: 84.00 AUD
So for a grand total of $129.00 AUD I have a screen that I am sure would rival a commercial one costing $4000.00+ AUD.