Friday, August 15, 2008

Projection Screen Fabrication - Part 2

Once the laminated parts cured I ripped them to a width of 3 1/2 inches on the table saw. The inside edges were beveled with a 45 degree router bit. The corners were mitered and slotted for plate biscuits that would help keep the joints aligned.

The ten-foot long curved frame members wound up having a little more flex than desired (maybe due to the Luann plywood) so I added curved ribs cut from 1x6 pine to the backsides. The piece on the left also has added blocks for the metal French cleat hangers.

The screen will be mounted on struts sticking straight out from the screen wall. this keeps the areas above and below the screen free from obstructions.

Once the I did a test assembly on the frame it became obvious that the mounting struts would have to be modified to be adjustable in order to allow the hanging cleats to be lined up straight and level.

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