Instructions To Make A Projector Screen

How To Make A Projector Screen

Build Your Own Projector Screen Like This One

Our method is similar to a giant artist's canvas: a wooden frame with the screen material stretched over it, and with a black contrast-boosting border placed around the edges for a professional look.

Grab Popcorn  And Enjoy!

Overview:

  1. Choose Aspect RatioLearn more about the native aspect ratio of your projector.
    1. 4:3  TV/Standard Size | 16:9  Widescreen/HDTV | 2.39:1  Wide Scope
      Aspect Ratio 4:3    Aspect Ratio 16:9    Aspect Ratio 2.39:1
  2. Choose SizeLearn more about the optimum size for your seating area.
  3. Select A MaterialUse our material comparison chart to learn which fabric is right for you.
  4. Make Your Own Projector Screen — Let's Get Started
  5. Gather Your Supplies

  6. Carl's Place Tools You Will Need Local Hardware Store
      (For a 5x9 Screen)
    1. Projector Screen Material
    2. Black Felt Tape

      Size 5x9-Foot
    1. Scissors or Utility Knife
    2. Heavy Duty Stapler
    3. Pocket Hole Jig
    4. Screw Driver
    5. Miter Saw or Miter Box/Saw
    6. Drill
    1. 30' Primed Back Band Trim to create a frame.
    2. 35' – 1x4 Select Grade or Higher Pine Lumber
    3. (2-4) Picture Frame Hangers
    4. (4) Floor Joist Braces (optional)
    5. Matte Black Spray Paint
    6. Heavy Duty Staples
    7. Screws
    8. Nails

    Please tell us what you think? | See our FreeStanding and Hanging Kits! | FAQ


For demonstration purposes, these directions will be for a screen with a 16:9 aspect ratio, because it will be used primarily for HDTV and it matches the aspect ratio of most home theater projectors. The size will be about 5'x9' as that is our most popular.


Instructions:

  1. You have chosen your aspect ratio, size and screen material & gathered your tools
  2. Determine viewable dimensions
    1. The material we have chosen is 110" wide. We will leave ourselves 5" of fabric to stretch over our wooden frame, so we'll have a viewable width of 105". Using the aspect ratio we must determine the height.
      1. 105" x 9/16 = 59.0625 or 59 1/16"
        We have our viewable dimensions of 105" x 59 1/16"
        1. An aspect ratio of 4:3 would be 105" x ¾ = 78.75 or 78 ¾"
  3. Calculate dimensions of wood frame
    1. Measure the black felt tape (It should be approximately 2".)
    2. Measure the back band trim (It should have an overhang of approximately 3/16" though this varies.)
    3. Take the viewable dimensions and add the width of the black felt tape and the overhang on the back band trim all the way around.
      1. Taking our viewable width of 105" and adding 2" twice and 3/16" twice, we get a total frame width of 109 3/8".
      2. Taking our viewable height of 59 1/16 plus 2" twice and 3/16" twice we end up with 63 7/16".
      3. Our frame dimensions are 109 3/8" x 63 7/16"
  4. Cut two pieces of pine that are exactly as long as the frame
    (our width is 109 3/8")
  5. Cut three boards that are 7" (twice the width of the 1x4's: 3 ½") shorter than the exact frame height (these will measure 56 7/16") - one piece will go in the center for stability
  6. Assemble the frame using your joinery method of choice. We prefer to use pocket screws and a simple pocket hole jig
  7. Fasten the floor joist braces in each corner for added strength (optional)
  8. Lay the screen material over the frame
  9. Using heavy duty staples, start on the top and place several staples in the center (1). Move to the bottom and place several staples in the center (2), stretching the fabric straight across.
  10. Move to the right side of the frame and place several staples in the center (3), stretching the fabric out from the center. Move to the left and place several staples in the center (4), stretching the fabric straight across.
  11. At the top add a couple staples, about 2-3 inches to each side of the original staples (5 & 6). Make sure to stretch with even tension out from the middle. Repeat at the bottom (7 & 8), right (9 & 10) and left (11 & 12) sides.
  12. Add 3 staples, again 2-3 inches apart, at the top of the frame (13-15 & 16-18). Repeat at the bottom (19-21 & 22-24), right and left sides. Again make sure to stretch with even tension out from the middle as shown in the diagram.
  13. Continue adding 2-4 staples, evenly spaced and rotating to opposite sides until the screen is completely secured all the way around the frame. Do not staple in a circle around the frame, always rotate to the opposite side with even tension.
    Watch Full Customer Testimonial Video or Jump to Demo on Stretching Your Screen Over a Wooden Frame. (Stretching begins at 3Min 13Sec)
  14. Cut the Back Band Trim with a Miter Saw or Miter Box/Saw to fit your frame. Back Band Trim is a piece of wood moulding that surrounds the exterior edge of the screen to create a professional looking frame.
  15. Spray paint the back band trim black and allow to dry
  16. Nail the back band trim to the frame
  17. Add the black felt tape, on top of the screen material, cutting with a scissors or utility knife – do NOT stretch the tape
  18. Hang on the wall using the picture hangers of your choice
  19. Grab the popcorn and a cool beverage (optional)
  20. Pop in your favorite movie or video game and enjoy!


Click Images to View Larger

Cut 5 Pieces

Screw Together

Floor Joist Brace

Screen Material

Staple to Frame
View Steps 9 - 12


Stretch and Staple to Frame
Watch Excerpt of Customer Video—Stretching Demo

Stretch from Middle Outward

Black Band Trim

Cross Section

Black Felt Tape

Picture Hangers


Click Images to View Larger



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