Make a 100" Screen for under $100
May 26, 2006,
How to build it.....
To collect the materials needed for this screen, you'll need to make one visit to a camera supply store, one trip to your home improvement store (Home Depot, Lowe's, or any other lumber and hardware store) and one stop at your local fabric store. Here is what you'll need:
One roll of 53" white seamless paper. This is the heavy roll paper that photographers use as backdrops for product photography, and it is available in camera supply stores. It comes in two widths-53" and 107". As luck would have it, the 53" size is perfect to accommodate a 100" diagonal 16:9 screen. (You can also order seamless paper online through several Internet suppliers.)Q: Can I use a light gray seamless paper instead of white in order to get better blacks with ambient light?
Step 1: Cut two of the poplar boards to 55.25" and the other two to 93.5", if you did not have it done at the store.
Step 2: Cut the ends of each board to a 45 degree angle.
Step 3: Cut the Velveteen fabric into four 6.5" wide strips, with two strips for the side of the frame being about 58" in length, and two strips for the bottom and top edges of the frame being about 96" in length.
Step 4: Lay each fabric strip on a clean, firm surface like a tile or linoleum floor, and center the corresponding section of the frame on top of it. Wrap and stretch the fabric around the board and staple it into place, so that the fabric is positioned with about a two-inch gap of bare wood showing down the center of each section of the frame (the fabric will lay over the back side of the frame sections with about ¾ inch on each edge.)
Step 5: Carefully trim the fabric at the ends to match the 45 degree angle of the boards. If necessary, use the glue to tack the fabric to the board at each end so that it is held flush with the 45-degree cut.
Step 6: Lay out the fabric-wrapped frame sections face down in a rectangle so you can join them together. Holding the frame sections firmly together, use one L-bracket at each corner and affix them to the exposed wood with six screws using the holes that are (hopefully) preexisting in the L-brackets.
Step 7: Roll out the seamless paper, and lay it over the frame. Starting at one of the 55" sides, staple the end of the paper into place along the exposed wood area. Maintaining even tension on the paper, continue to staple it up the long edges of the frame. One staple every 9" is adequate to hold it in place. Once you reach the opposite end of the frame, trim the paper from the roll, and staple the final edge into place.
There it is. You now have a lightweight 100" diagonal 16:9 projector screen that you can hang on a wall with picture hanging hardware attached along the top edge of the frame. Power on your projector, turns the lights off, and enjoy!
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