A projector screen is a necessity for any home theater setup, and there are a variety of ways to build one. The most popular and simple way is to frame the screen with wood strips. While the motorized projection screen do not require a static projector screen frame but most of the fixed projector screens do. This method is easy to do, and it results in a clean-looking, professional-grade projector screen.
Steps to Build a Projector Screen Frame
Here’s how to build a projector screen frame:
- Estimating the Wooden Frame Dimensions
The dimension of the material you are going to buy depends on the screen size you need. There are different types of projector screens and each comes with different dimensions and aspects to consider.
Once you finalize the width, to achieve the viewable height you have to multiply the required width with the given aspect ratio.
You have to order the raw materials depending on what kind of installation you are proceeding with. For example: You might need a higher or lower viewable width depending on the style and size of your window. It is important to have the enough fabric for stretching over our wooden frame easily. If you need 105″ wide viewing area, take an additional 5” into account to tuck into the projector screen leading to 110” wide cloth.
- Calculating Wood frame dimension
Once you access the required viewable dimension, calculate the width of trim to add it to the given dimension.
For Zero Edge look: Keep frame dimensions will be equal to or smaller than your measurements.
Cut two pieces of wood that are the same length as the frame. We suggest utilizing 1×4’s since they are readily available and inexpensive.
Finally, cut three boards – one for the center to ensure stability and the other two for sides. The dimension for these boards are 7″ shorter than the frame height specified.
- Staple the screen material after stretching
- The edges and corners of the frame shall be smooth. You can use the sand technique to avoid any tearing or snagging while stretching.
- With frame as a top, place the screen gently on the flattened surface like floor.
From the top, start by stapling in the middle and work your way down (1). Continue working your way down and place additional staples in the center of the cloth (2), which should be stretched straight across.
Extend the cloth to the left, stapling it across in multiple places. Stapling the fabric on both sides will cause wrinkles, so move over to the right side of the frame and stapled it there instead. Try to stretch the cloth towards the center to get a clean look and then place several staples.
Make sure that there are no ripples in the cloth at the center, before stapling it to the frame.
At the top, add a few staples on each side of the existing ones (5 & 6). Strech the equal tension which is carved from the middle. Repeat on the bottom (7 & 8), right (9 & 10) and left (11 & 12) sides.
You should add the three staples at the top of the frame which are almost 3” apart. . Repeat on the bottom (19-21 & 22-24), as well as on both sides. Make sure to stretch from the center with equal tension as shown in the illustration once again.
Secure each screen section to the frame with 2-4 staples, evenly spaced and alternating sides until the screen is fully encircled around the frame. Staple in a circle around the frame; never rotate to the opposite side with even tension.
Pro Tip: Do not wrap our thicker or non-tensioned materials. Permanent damage will be caused if you fold or pinch a thick material. If you’re wrapping the item over your frame, make sure it’s a tension-mounted cloth like FlexiWhite, FlexiGray, and Ambient Light Rejecting (ALR).
4. Using Frame Finishing
- If you’re cutting the protective plastic film off, a Miter Saw or Miter Box/Saw is required. The Back Band Trim is a wood molding that surrounds the screen’s exterior edge and gives it a high-end appearance.
- Allow the spray paint to dry on the back band trim before polishing it.
- To the frame, nail the back band trim.
- Attach the black felt tape over the screen cloth, cutting with a scissors or utility knife and do not stretch it.
- You can also use picture hangers
- Your projector frame is ready!