Originally Posted by TriChiro
So, Great with the humor and with the DIY....You may just have saved me a lot of hassle keeping my kids (2 and 4) from swinging the screen daily...Its in a dedicated theater room so your idea looks great. What diy tool would you recommend to make the 1 1/2" cut-in on the hanger.
I'd use a Skill Saw myself, being the depth and width of the "notch" is well within the boundaries of even a 5-1/2" Mini Blade. But be careful to support/brace that piece so that it doesn't move while you slice and dice, especially when you do the cut on the "End". Use a new and sharp blade with a Tooth number best for "Paneling" as that blade will be less inclined to make the wood jerk toward the rotation of the Saw. The Fine tooth Blade (120 Tooth) will also give you a exceedingly smooth cut.
Set the depth of the Blade to the required depth, then simply cut along a visible measured Line. Should be no problemo.
Secondly, how would the dowel rod attach to both the wall and the frame?
The inclination for any such material that is hung via a support that is so far toward the Top will be for the Bottom to pitch inward toward the wall. If you didn't have a Urchin Infestation to deal with, gravity and the opposing rearward tension would hold the screen in place against the "end" of the protruding pole. Been there....done that too.
But as that is not the case here, and short of using 2" x 2" Lumber, and making it as strong as a Jungle Gym, here's what I suggest.
At the point where the interior Braces are, install a simple "Closet Pole Hanger Bracket" on the Brace, and a "Closed Circle" Closet Pole Bracket opposite to that point on the Wall....should be easy enough to manage if the location was well thought out as to the spacing/location of the Interior Upright Screen Braces, as they should be directly opposite a Stud anyway so the Wall hangers also share that "support". Insert the Pole in the Bracket that is on the Wall using 1-5/8" Screws, then slide the other end of the Pole down into the "U" Cup Bracket. Those Brackets have small holes in each side or the bottom so that they can be locked into place using a small Brass Screw.
Certainly not Brain Surgery, but more akin to making a Crutch to lean on.
ps. the WA dimensions are 107 x 60...
My kind of Screen. Can you Miter Cut lumber? Can you access a actual Miter Saw? (....that will make doing precision cuts a snap!) You really want to do so in this case, for the Screen Frame, wall hangers, and any eventual Velvet Trim will all need such in order to have the strongest possible junctions. If you cannot do so, let me know because there are other ways....ways that involve using 3" Coarse Threaded Utility Screws shot through one 2" x 4" deep into another laid over it. I hope you don't have to go there because that sort of "build" looks almost "Tree House" like and is not in keeping with what should be in a Dedicated Theater Room. After all, your "Floater" will attract a lot of attention....and subsequent "critical' inspection, so you want a clean, finished look about the whole affair.
I know it sounds like a hassle, but sanding all your Wood at least lightly, then painting it Black (...outside surfaces of the Screen Frame and Braces & protruding "Hanger" pieces) and painting the Lumber on the Wall the wall color will add a real nice touch that bespeaks that you took a little bit of "extra" care to make it look "extraordinary"
pps. I feel indebted to you...Any medical questions, I'm a dr.......
If you only knew, you'd retract that offer quickly. If you think my posts about "DIY Screen Making" can get long and involved........well, let's not go there!
This little project is in keeping with exactly the sort of thing I like to see done in such demanding situations. It will be adjudged "different and innovative" by your Peers (...if that matters...) and so add to the degree of your own personal satisfaction index. Your already ahead of the Game by opting to make a Screen out of a unexpected material that will perform far above yours and everyone else's who sees it expectations. Just be sure to get a "Killer Deal" on a PJ, calibrate it so as to get an astounding image, and everything will come together to make your Theater a cut & above the ones your Neighbors and Friends spent "too much for too little" for.
That's the best part! Watching them shake their heads in shame and envy. (...after their Eyes pop back into their heads.)