102" DIY screen project done

[YOyoYOhowsDAjello]

Hey folks, I just got done with the border and masking system for the screen I made during the summer so I thought I'd post some pictures

Basic Info

The screen is 102" for 16:9 and is made of Blackout Cloth. The material is stretched over a wooden frame with the help of a staple gun. The border and masking system are made of pink insulation board covered in black fidelio velvet.

I'm using a Panasonic AE900U as my projector and my content is mostly DVDs.

The Screen

Unfortunately I didn't really take any pictures during the process, but it was pretty easy to do. I just built a frame out of 1x2s with some metal brackets (1 "L" in each corner and 1 "T" at each end of the middle brace bar). Next I stretched a few yards of Blackout Cloth (from Jo-Ann Fabrics... yeah it was scary in there) around it as if I were making an artist's canvas.

Some pictures of the screen

There are a lot of good options for screen material other than what I used.
There are a lot of options listed here

Planning the Border and Masking System

Ok, so the screen looked pretty good on its own, but I knew from my own experience that a border and masking system really makes things pop.

Back at the old place last year I made a basic border and masking system for my 76" Infocus 4805 setup and it improved things a lot.

Pics from last year:
16:9
4:3
2.35:1

I was fairly happy with how it worked, but it was very flimsy and wasn't really "black" enough to capture any overlap of the projected image with the border.

This year I got around to researching what would be a good material to use and I came to this thread:
http://archive2.avsforum.com/a...00495&highlight=velvet

It's incredible how black this stuff is.

I took some pictures vs. some "black" speaker grilles and my "black" subwoofer.
Black Fidelio vs. Onix Rocket RSC200 grille
Black Fidelio vs. SVS

I decided to test it for its intended purpose and I was not disappointed.
Black Fidelio vs. my AE900U image
I circled the two parts where the "wrong side" of the fabric was being hit by the image. That looks black on its own too, but nothing compared to the right side

Before I ordered my velvet though, I wanted to make sure I had the right amount. I also didn't want to buy more than I needed since at $20/yard it was rather expensive

I planned out the parts and sizes I was going to need for the velvet an eventually the insulation board that would be used to support it.

Plans

Making the Border and Masking System

I think I covered the process pretty well visually

Constructing it

The pink foam insulation is 3/4" thick. Ladybuggy and I had to fit two 4'x8' boards worth of it in a Hyundai Elantra, so we kind of had to have them cut to roughly the right size at Home Depot.

In addition to the insulation and velvet, my other major construction item were 20 Neodymium Magnets
Might as well throw up a link

The magnets were strong enough that I'm able to support each masking panel with only two magnet-to-magnet connections. In my previous masking system, I had used velcro to secure my panels. I knew that even the "fuzzy side" of velcro wouldn't be as black as my fidelio velvet, so I needed an invisible way to connect the panels easily and magnets seemed like the easiest way to do it.

So the border has 8 magnets in it while each masking panel has 2. The panels are secure enough that I don't think I have to worry about them falling off even if I turn my sub up

Finished Product

So anyway... all went well and I now have my project completed. I took a couple pictures of each aspect ratio.

Done!

Some shots of it in action

The border and masking system didn't show up too well in these shots due to my camera, but I assure you that it really helps the image to have the border there.

16:9 material
Aliens
Nemo

4:3 material
Star Trek TNG
This looks pretty bad compared to the rest. We're on Season 2 right now and I'm hoping that things improve visually as the seasons progress. It looks much better in motion (as does all of this material) but these looked especially bad in these shots

2.35:1 material
Alien
THX logo

Ok, I'm done

 

[KLin]

This thread deserves a sticky.

EDIT: Nice job BTW :thumbsup:

 

[AAjax]

Originally posted by: KLin
This thread deserves a sticky.

EDIT: Nice job BTW :thumbsup:

No kidding

 

[dug777]

Originally posted by: KLin
This thread deserves a sticky.

Gimme a second...oh yeah, that should do it


Sweet screen yoyoyoyoyoyoyo :beer:

 

[PurdueRy]

This can only mean one thing....Jello is a racist.

Keeping the white screen down through masking...despicable!

 

[AAjax]

Originally posted by: dug777

Originally posted by: KLin
This thread deserves a sticky.

Gimme a second...oh yeah, that should do it


Sweet screen yoyoyoyoyoyoyo :beer:

Welcome back

 

[YOyoYOhowsDAjello]

I dunno, a sticky would seem kind of odd for this :laugh:

PurdueRy... I guess I did go as black as I could

 

[BillyBatson]

d00d this thing is freakin AWESOME!
what was the foam padding/insulation used for just the to wrap the velvet around for the masking?
and where on the screen are the 8 magnets on the frame or behind the blackout fabric?
i want to trade my plasma for a projector now

 

[YOyoYOhowsDAjello]

Originally posted by: BillyBatson
d00d this thing is freakin AWESOME!
what was the foam padding/insulation used for just the to wrap the velvet around for the masking?
and where on the screen are the 8 magnets on the frame or behind the blackout fabric?
i want to trade my plasma for a projector now

Yeah, the insulation was just to create a good material that was easy to cut, light, and rigid enough to hold the fabric up. Some people use wood for their borders, but I knew it was going to be very difficult to easily mount masking panels made of anything that heavy, so I went foam insulation for the whole structure including the borders.

Oh... I forgot to mention that originally I had planned on making a 6" border, but after thinking about it some more I thought 4" would be plenty for a screen this size. I think somewhere in the 3" to 4" range looks good for a ~100" screen.

For comparison, here are some other DIY screens (2" and 3" vs my 4")
http://www.avsforum.com/avs-vb/showthread.php?t=732107

I guess it's all about personal preference on how thick to make it. I'm quite happy with how substantial my screen looks now.

Added a picture of the Magnet Locations for you:
<a target=_blank class=ftalternatingbarlinklarge href="https://mywebspace.wisc.edu/spmclaughlin/web/7%20DIY%20Screen/3%20Border%20and%20Masking%20System/22%20Magnet%20Locations.JPG">https://mywebspace.wisc.edu/spmclaug......System/22%20Magnet%20Locations.JPG</a>
(They are behind the layer of velvet on the foam border, attached with my favorite... hot glue)

I was originally planning on 4 magnets per panel, but two was plenty

 

[MBrown]

Wait so you add more black borders to the screen to change the aspect ratio? Do you have any pics of it while playing 360?

 

[So]

Jello, I'm going to be bugging you SO MUCH once I graduate and get a place to build a home theater.

GJ, and I approve of your choice of Alien and Aliens for your demos.

 

[YOyoYOhowsDAjello]

Originally posted by: MBrown
Wait so you add more black borders to the screen to change the aspect ratio? Do you have any pics of it while playing 360?

Yeah, when I'm watching 4:3 material, I put up the two 4:3 masking panels so the image has black velvet on all sides again. 2.35 I put up the two 2.35:1 masking panels and again the image has velvet surrounding it.

If I did not have the masking panels, I would have "black" projected onto the screen in those areas of the 16:9 screen and I would lose the perceived image enhancement that the black border provides. I would still have velvet on 1/2 the sides for images of different aspect ratios, but fitting the screen to the image aspect works best.


I don't have any 360 pics because all we have is N64 and PS2

 

[YOyoYOhowsDAjello]

Originally posted by: So
Jello, I'm going to be bugging you SO MUCH once I graduate and get a place to build a home theater.

GJ, and I approve of your choice of Alien and Aliens for your demos.

Now I need to actually watch the series again (I didn't actually watch the movies, I was just using them to make sure I was getting everything set up right for where my projector is and then got carried away with the pictures

 

[dawnbug]

I'm sitting across from the screen right now, and it seems even bigger with the borders up than it used to without, as well. I think it was a really worthwhile project.

 

[raptor13]

That screen is okay, I suppose. But how, really, am I supposed to be impressed by a lowly 102" screen when I can walk into my living room and see:

A projector,
a screen,
and a sense of scale?



Actually, YoYo, I have to commend you and your project. My setup is nearly the same as yours. I'm running the AE900U :heart:, a blackout cloth screen, and an SVS woofer. That guy can be seen in the third picture. There are two main differences, however.

1) My black border is wood, as you mentioned some are.
2) My screen is a whopping 110 INCHES!!! 102"? Child's play!

Suck on that, Jello! MWA HA HA HA HA!!!!

 

[MisterJackson]

Originally posted by: raptor13
That screen is okay, I suppose. But how, really, am I supposed to be impressed by a lowly 102" screen when I can walk into my living room and see:

A projector,
a screen,
and a sense of scale?



Actually, YoYo, I have to commend you and your project. My setup is nearly the same as yours. I'm running the AE900U :heart:, a blackout cloth screen, and an SVS woofer. That guy can be seen in the third picture. There are two main differences, however.

1) My black border is wood, as you mentioned some are.
2) My screen is a whopping 110 INCHES!!! 102"? Child's play!

Suck on that, Jello! MWA HA HA HA HA!!!!

I know you're being sarcastic and all, but his owns yours simply because it's neat and well constructed.

Your's isn't BAD, it's just his is BETTER

 

[PlatinumGold]

Originally posted by: raptor13
That screen is okay, I suppose. But how, really, am I supposed to be impressed by a lowly 102" screen when I can walk into my living room and see:

A projector,
a screen,
and a sense of scale?



Actually, YoYo, I have to commend you and your project. My setup is nearly the same as yours. I'm running the AE900U :heart:, a blackout cloth screen, and an SVS woofer. That guy can be seen in the third picture. There are two main differences, however.

1) My black border is wood, as you mentioned some are.
2) My screen is a whopping 110 INCHES!!! 102"? Child's play!

Suck on that, Jello! MWA HA HA HA HA!!!!

is there a ratio? how far away the projector has to be from the screen to get a certain image size?

 

[raptor13]

Originally posted by: MisterJackson

I know you're being sarcastic and all, but his owns yours simply because it's neat and well constructed.

Your's isn't BAD, it's just his is BETTER

You're absolutely right. Mine is definitely just thrown together. The problem is that I'm living a very transient life at the moment. I just moved to Portland, OR a couple months ago and will be here - at most- for a year. Then it's off to another apartment and another attempt at throwing together a theater.

It's going to be a while before I can buy a house. But when I do.... :evil:

 

[YOyoYOhowsDAjello]

Originally posted by: MisterJackson

Originally posted by: raptor13
That screen is okay, I suppose. But how, really, am I supposed to be impressed by a lowly 102" screen when I can walk into my living room and see:

A projector,
a screen,
and a sense of scale?



Actually, YoYo, I have to commend you and your project. My setup is nearly the same as yours. I'm running the AE900U :heart:, a blackout cloth screen, and an SVS woofer. That guy can be seen in the third picture. There are two main differences, however.

1) My black border is wood, as you mentioned some are.
2) My screen is a whopping 110 INCHES!!! 102"? Child's play!

Suck on that, Jello! MWA HA HA HA HA!!!!

I know you're being sarcastic and all, but his owns yours simply because it's neat and well constructed.

Your's isn't BAD, it's just his is BETTER

Oh snap

I see some more differences:

Where's your masking system?

And... do I see a 4.1 system? :Q ( please say it ain't so for the sake of the people non in the sweet spot )

 

[YOyoYOhowsDAjello]

Originally posted by: PlatinumGold

Originally posted by: raptor13
That screen is okay, I suppose. But how, really, am I supposed to be impressed by a lowly 102" screen when I can walk into my living room and see:

A projector,
a screen,
and a sense of scale?



Actually, YoYo, I have to commend you and your project. My setup is nearly the same as yours. I'm running the AE900U :heart:, a blackout cloth screen, and an SVS woofer. That guy can be seen in the third picture. There are two main differences, however.

1) My black border is wood, as you mentioned some are.
2) My screen is a whopping 110 INCHES!!! 102"? Child's play!

Suck on that, Jello! MWA HA HA HA HA!!!!

is there a ratio? how far away the projector has to be from the screen to get a certain image size?

http://www.projectorcentral.com/Panason...T-AE900U-projection-calculator-pro.htm

 

[YOyoYOhowsDAjello]

Originally posted by: raptor13

Originally posted by: MisterJackson

I know you're being sarcastic and all, but his owns yours simply because it's neat and well constructed.

Your's isn't BAD, it's just his is BETTER

You're absolutely right. Mine is definitely just thrown together. The problem is that I'm living a very transient life at the moment. I just moved to Portland, OR a couple months ago and will be here - at most- for a year. Then it's off to another apartment and another attempt at throwing together a theater.

It's going to be a while before I can buy a house. But when I do.... :evil:

I'm waiting for a house to get things done right too :evil:

I've moved all my stuff twice a year for the past 5 years.
Thank goodness I had the sense to figure out I should ditch the wega :laugh:

 

[PlatinumGold]

Originally posted by: YOyoYOhowsDAjello

Originally posted by: PlatinumGold

Originally posted by: raptor13
That screen is okay, I suppose. But how, really, am I supposed to be impressed by a lowly 102" screen when I can walk into my living room and see:

A projector,
a screen,
and a sense of scale?



Actually, YoYo, I have to commend you and your project. My setup is nearly the same as yours. I'm running the AE900U :heart:, a blackout cloth screen, and an SVS woofer. That guy can be seen in the third picture. There are two main differences, however.

1) My black border is wood, as you mentioned some are.
2) My screen is a whopping 110 INCHES!!! 102"? Child's play!

Suck on that, Jello! MWA HA HA HA HA!!!!

is there a ratio? how far away the projector has to be from the screen to get a certain image size?

http://www.projectorcentral.com/Panason...T-AE900U-projection-calculator-pro.htm

so, you have to choose a projector first either based on feature set etc and then figure out the distance you have to work with in the room you are going to put it in and THEN build the screen right?

something like that? i'm interested in doing a project like this also. any recommendations for a projector?

 

[purbeast0]

YoYo's screen > raptor13's

also raptor, your couches are like 6 feet away from a 110" screen. seems a lil too close for my liking ...

 

[YOyoYOhowsDAjello]

Originally posted by: PlatinumGold

Originally posted by: YOyoYOhowsDAjello

Originally posted by: PlatinumGold

Originally posted by: raptor13
That screen is okay, I suppose. But how, really, am I supposed to be impressed by a lowly 102" screen when I can walk into my living room and see:

A projector,
a screen,
and a sense of scale?



Actually, YoYo, I have to commend you and your project. My setup is nearly the same as yours. I'm running the AE900U :heart:, a blackout cloth screen, and an SVS woofer. That guy can be seen in the third picture. There are two main differences, however.

1) My black border is wood, as you mentioned some are.
2) My screen is a whopping 110 INCHES!!! 102"? Child's play!

Suck on that, Jello! MWA HA HA HA HA!!!!

is there a ratio? how far away the projector has to be from the screen to get a certain image size?

http://www.projectorcentral.com/Panason...T-AE900U-projection-calculator-pro.htm

so, you have to choose a projector first either based on feature set etc and then figure out the distance you have to work with in the room you are going to put it in and THEN build the screen right?

something like that? i'm interested in doing a project like this also. any recommendations for a projector?

Yeah, I like the idea of researching a projector, buying it, and then figuring out exactly what size screen you like based on the throw distance and seating distance before getting the screen done.

If you're awesome at planning and know what kind of viewing angle you want, you could do it all at once, but I found the steps method easier.

I'm at about 40 degrees for my viewing angle. http://www.myhometheater.homestead.com/viewingdistancecalculator.html

There are a lot of good projectors.

What's your pricerange?

 

[raptor13]

Originally posted by: PlatinumGold

is there a ratio? how far away the projector has to be from the screen to get a certain image size?

Yes, every projector has a ratio (or range of ratios) between throw distance, i.e. how far away the projector is from the screen, and image size. Some projectors have fixed ratios, usually the inexpensive ones and the really, really expensive ones, while others have some adjustability, like the Panasonic AE900U both Jello and I are using. For reference, my throw distance is about 16 feet.

This projector also has some pretty good optical adjustments which allow the image to optically be zoomed in or out. They call it a 2x zoom for whatever it's worth. The point is that it allows for extreme flexibility in choosing image size regardless of throw. On top of that, the Panny can also optically adjust the vertical and horizontal picture location which virtually eliminates the need for digital keystone correction.

You'll notice my projector is mounted horizontally flat above a door. With a normal projector, I'd have to aim the projector down and use keystone correction. Not so with the Panny! Keystoning is the enemy of picture quality so these optical adjustments are pretty damn nice! Once again, Panny = :heart: