Giant Projection Screen

I recently built a projection screen to go along with my projector. I used to project onto the wall of my apartment, but the walls aren't pure white or perfectly flat. This Instructable will show you how to build a frame, stretch a screen across your frame, and hang the frame on the wall. I ended up with a perfectly flat and white screen. Follow my instructions and with a little care you will end up with an awesome screen.

If you buy everything you need for this project from home depot and the screen from here (minus the tools) it will cost less than $100.

First, a few warnings; hand tools, power tools, saws, and staplers are dangerous. Please follow all the safety information on your tools. The end product of this Instructable is a heavy (~40lb) screen that will hang on your wall. If you have kids or pets make sure the screen is attached to your wall in such a way that they wont be able to pull the screen off the wall.

Materials required:
QTY. Item
1 Projection screen approx 110x66
4 10' 2x4
4 90 Degree Brackets
8 Corner Brackets
2 Eye hooks
1 9ft spool of 100lb picture hanging wire
1 200lb picture hanging hook
1 Sheet sandpaper
? 2 1/2 inch wood screws (I didn't count how many I used)
? 1 inch wood screws (I didn't count how many I used)
? Staples for a heavy duty stapler (I didn't count how many I used)

Tools required:
Miter saw and miter box or a motorized miter saw
Heavy duty stapler
Measuring tape
Drill or a screwdriver
Pencil

Step 1 Screen Information, Measure Screen, and Pick Dimensions

The screen material that I'm using in this project is blackout cloth. It is a matte white that is very opaque. You might be able to find it in a local fabric shop, but probably not in the size that I'm using. I bought my piece of blackout cloth from Carl's Place. The price was good and shipping was pretty fast.

Lay out your cloth and measure it. My piece of cloth is 110x66" (pic 1).

We are going to build a frame out of 2x4s (which are actually 1.5x3.5), and we want the cloth to wrap all the way around the edge of the 2x4. That means we need our frame to be a minimum of 7 inches less wide and long than the cloth. To be on the safe side we decided to build our frame 100x56.

Comments

[jkketchup]

This is nice, what is website you bought fabric from?

[gregr]

I bought the fabric from here.

[lemonie]

Very good. L