Originally Posted by heilgid
After doing further research i have realized I'm going to change the direction of my screen completely xD
It seems that it would be worth my money to invest in some sintra or other solid like substrate and drop the BOC idea completely!
I then will have a screen that will theoretically last forever and wont have to worry about stretching warping etc.
To me it seems like it would be worth the time and money!
A wise and well considered choice.....mostly. Read on.
As far as the frame goes:
My dad got some 2x2 aluminum square extrusion I'm going to use as the frame; thanks pops.
So the new plan is as follows:
1. Construct frame with aluminum extrusion
Pop had your best interest in mind for certain....but you gonna have issues trying to support the Sintra on such a narrow edge. Sintra IS
a worthy choice mind you, but your heading down a path that will result in large areas of unsupported material that can...and will tend to bow in/out
The Extruded Aluminum supporting Frame? I'd suggest you fergitabowdit and don't cut anything up so you cannot return it.
2. Find a good substrate (bigger than 4x8, preferably 5x10)
Well that should be easy.....the Sintra you want comes in 5' x 10' x 6mm thickness.(...you do NOT want the 3mm variety...) Post (or PM) you location and I'll locate a Plastic Supplier closest to you who can accommodate you needs at the lowest possible cost. That's always the best possible start.
3. Mount the substrate to my frame
I could wax on about the issues you'll face...but why bother?
Instead....recoup the expense of the Aluminum and spend it instead on another sheet of 5 x 10 x "3mm" Sintra ( approx $50.00 )
So let's determine the size of your screen. The biggest possible size you can manage is 122" diagonal (107" x 60") So you have the sheet of 6mm Sintra cut to those dimensions. Then...you have the 3mm Sintra cut down into 4 - 15" x 113" strips. 2 of those strips will serve as the Top & Bottom Frame, with 3" protruding outside the Top and Top Corner/Side perimeters.
With 30" of the 60" height already accommodated on the sides, you can take one of the remaining 113" x 15" strips and cut it into 2 30" x 15" strips. Those will then be inset along the sides to fill in the space between the Top & Bottom Strips, and their protruding 3" extensions.
The 3mm Strips will be glued to the 6mm Sintra using 3M Super 77 Adhesive.
Let the assembly dry 24 hours. DO NOT rush it!
The 3" wide 3mm Borders serve a triple purpose.
1. They serve to stiffen the perimeter of the Sintra.
2. You can attach the Sintra to the wall using Sharp Point Truss Head Screws shot through the 3" Boarder.
3. It acts as both a Edge guide and attachment surface for the Trim (1/2" x 3.25" Velvet Wrapped MDF Baseboard) and such Trim can be attached with 1.25" Bright Finish nails that are "set" just below the Velvet Covering.
4. Build a frame with black velvet that could easily be removed in the future.
Such small nails, while more than adequate to hold the Trim in place, can easily be pulled out of the underlying Sintra/Drywall.
5. Use the screen as is until I can afford some good paint; most likely MaxxMudd.
If we can obtain for you a sheet of 6mm Sintra that is at least pristine
on one side, that surface will suffice as far as being a reasonably good Screen surface in a temporary sense. Remove the Trim later and you can simply spray on top of it (Sintra) with consummate ease.
1. What options do I have for substrate that's bigger than 4x8, and
that I could use WITHOUT painting for a few months.
2. Whats the best way to mount my substrate to my aluminum frame?
The smaller the Screen...and that means a less unsupported span of plastic...the less concern there would be as far as attaching the Sintra around the Perimeter. But 107" x 60" is not "small", and in a word, any 2" wide lateral or vertical "Interior" supports that you attempt to attach the Sintra to will almost assuredly manifest themselves as ridges visible on the "Screen surface" side.
Now that's not saying it can NOT
work...what's being said is that a successful effort is at best problematical, and at worst, the ruination of the attempt.
Thanks again everyone! The people in this forum has been extremely knowledgeable, and helpful!
And sometimes we can carry very sharp pins that tend to prick the balloons our fellow DIY'ers have floating about. But seldom is the case that we do not have another, more buoyant and brightly colored one waiting.
Why, we even have all the Hot Air you need to inflate it!
(Don't worry....we don't allow "Hindenburgs" on the DIY Screen Forum.