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Do-It-Yourself (DIY) CRT Projection Screen

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 area.

Click Here for a guide to stretching canvas that I used when stretching the blockout material over the frame.


Finished 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)
Corner of frame

Centre Support 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)
Material Detail

Positioning frame on material 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)
Screen Corner

Shot 1 finished product! 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)
Shot 2 finished product!



Here is a list of the materials that I used:

Frame:
  • 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
Screen:
  • 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.
 




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