My DIY 110" BOC screen - AVS Forum
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post #1 of 32 Old 01-17-2012, 12:38 PM - Thread Starter
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Finally got the time to make my screen. I bought the Roc-lon black out cloth from Joannes Fabric. Widest they have is 54" so I got that. I went to Home Depot and got the wood to make a 110" screen which would mean 96" x 54". From what I read the 54" screen would be able to stretch enough to fit around the back side of the frame to staple, I was wrong. I was only able to stretch it out to the sides. Not a huge deal but in hindsight I would shave an inch off my frame to make it work. I bought 5 8' x 3" (really measures 8' x 2.5") and cut them to size. I also bought 4 "L" brackets, 2 "T" brackets, screws, staple gun, and staples. It all came out to $80 after tax. Here are some pics bellow.

Now I just need to figure out how to hang it and if I'm going to build a black frame around it or just stick black felt around the border. I am leaning towards the black frame around it so I don't waste valuable screen real estate.

I'll post the finished pics when I get the black border on it and hang it. Oh and I have an Epson 8130.

My little helper framer



Shows how much extra I had to stretch


Getting close


All done
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post #2 of 32 Old 01-20-2012, 04:52 PM
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Nice job. So do you just have this hanging on screws? Or how did you mount it to your wall?
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post #3 of 32 Old 01-21-2012, 12:34 PM
 
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If you have folding marks, you can use a steam iron set on steam and hold it about an inch from the cloth and move it around and should see the folds disappear. I'd opt for the black frame to make the screen as big as possible. Down the road you might want to try spray painting it with some of the paint mixes on this forum, or just roll a couple of coats of Behr Ultra white flat enamel on it making sure you don't get roller marks to add more pzazz to your image.
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post #4 of 32 Old 01-25-2012, 03:26 PM - Thread Starter
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Didn't mount it on the wall yet. Hope to do it tonight before the Lakers vs Clippers game. I just got a picture hanging kit for $8 at Home Depot that says can hold up to 50lbs so I think it will be ok. It has 2 D rings to screw to the back of the frame and 2 hooks that are held to the wall with 2 tiny nails. I hope it holds...
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post #5 of 32 Old 01-26-2012, 12:33 AM
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That sounds "iffy". Why not use a "HangMan"?

http://www.homedepot.com/webapp/wcs/...cStoreNum=8469

....and have no worries whatsoever.

To quote James T. Kirk;
"I'm laughing at the superior intellect"
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post #6 of 32 Old 01-26-2012, 12:27 PM - Thread Starter
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Quote:
Originally Posted by MississippiMan View Post

That sounds "iffy". Why not use a "HangMan"?

http://www.homedepot.com/webapp/wcs/...cStoreNum=8469

....and have no worries whatsoever.

Hmmm. I might have to check that out. Here is what I bought.

http://www.homedepot.com/h_d1/N-5yc1...atalogId=10053

Think it's safe MM?
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post #7 of 32 Old 01-26-2012, 02:38 PM
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Quote:
Originally Posted by lakersin2025 View Post

Hmmm. I might have to check that out. Here is what I bought.

http://www.homedepot.com/h_d1/N-5yc1...atalogId=10053

Think it's safe MM?

Angled Nail Brackets are reasonably secure, but not nearly so much as a Hangman Bracket. Two Hangman s, one at each top corner, and it would take "The Big One" to make it fall off the wall.

Actually, I'm fairly certain you'd find the Wall lying Flat with the Screen still attached. Hopefully you wouldn't be starting up at the screen from underneath.

The real PITA about Nail & Loop Brackets is that they really are more difficult to get perfectly level, to get the loops up onto the Nails since they have to be spaced so far apart, and the assembly is inclined forward a bit.

Your call....but as for me...I'd be a'callin' the Hangman in to do my dirty work.

Humboldt Co. eh? Nice.

To quote James T. Kirk;
"I'm laughing at the superior intellect"
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post #8 of 32 Old 01-26-2012, 04:18 PM
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I use a set of closet door hinges.
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post #9 of 32 Old 01-27-2012, 12:25 PM - Thread Starter
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Anyone have any suggestions on putting a black velvet/felt frame or border around this puppy?
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post #10 of 32 Old 01-27-2012, 01:08 PM
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Why not go borderless if the wall behind the screen is a dark color?
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post #11 of 32 Old 01-27-2012, 02:23 PM - Thread Starter
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Quote:
Originally Posted by lewke View Post

Why not go borderless if the wall behind the screen is a dark color?

The wall is that cream color in my last picture.
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post #12 of 32 Old 01-27-2012, 02:52 PM
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Quote:
Originally Posted by lakersin2025 View Post

The wall is that cream color in my last picture.

Ah...I thought it might be the darker walls in the first pics.....guess not....
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post #13 of 32 Old 01-29-2012, 10:47 PM
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Could use gaffers tape.
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post #14 of 32 Old 01-30-2012, 12:38 AM
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Ahhhhh..............lakersin2025,

You inspired me.

My Church's Youth Ministry had a 30 year old + 125" x 94" Da-Lite Da-Snap Matte White Screen they were using....that was in deplorable condition. Rips, stains, even Melted Vinyl where squiggly lines of Expanda-Foam had come in contact with it.




It was every bit as bad as it looks.


But at some time in the past, someone had wrapped the original Da-Snap Aluminum Frame with stout, Black painted 1/2" thick "Outside Corner" Trim. I thought to myself. "Myself....why not re-wrap that Frame with BOC and paint it?". Just leave the existing material attached (...for increased tension support for Frame...) since it is recessed from the Wood Trim and wrap the BPC around the outside edges.

So....I ordered some 110" x 144" BOC and went to work, wrapping the first BOC Screen of my career. 157"s of "What iffin....." if there ever was some.

Thing was/is...it's turned out PDN as of now, considering my sore knuckles I got from rolling the Fabric against the Frame to stretch it out. Seems that when your stretching out a 10' x 8' area of BOC with your hands all by yourself, ya gotta employ both the Kung Fu Grip and the Deadly Wrist Twist technique.

Bit nary a wrinkle in sight, and I got the material "Drum Head" tight. I'll insert a image of the wrapped Screen before I start a'paintin'

Next up....Silver Fire v2.5 2.0

To quote James T. Kirk;
"I'm laughing at the superior intellect"
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post #15 of 32 Old 01-30-2012, 07:14 AM
 
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Quote:
Originally Posted by MississippiMan View Post

Ahhhhh..............lakersin2025,



So....I ordered some 110" x 144" BOC and went to work, wrapping the first BOC Screen of my career. 157"s of "What iffin....." if there ever was some.

Bit nary a wrinkle in sight, and I got the material "Drum Head" tight. I'll insert a image of the wrapped Screen before I start a'paintin'

Next up....Silver Fire v2.5 2.0

Looking forward to seeing the results...
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post #16 of 32 Old 01-31-2012, 03:17 PM - Thread Starter
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[quote=MississippiMan;21568996]Ahhhhh..............lakersin2025,

Haha. I had to pull so hard my thumb nails separated from the skin. Just now back to normal. That screen looks beat dude. Can't wait to see how it comes out. Still haven't hung mine. Think I'll hang it then decide if I need black border around it.
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post #17 of 32 Old 02-10-2012, 03:54 PM - Thread Starter
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So I ended up hanging the screen without black boarder just to get it up on the wall. Just used the picture hanger. So far so good. It's amazing how much better the picture is that on my white wall. I was picking up all the detail in the plaster. Plus it was high gloss paint so I was getting hot spotting like a mofo. Now it's nice and smooth and still bright and I only use eco mode. Here's a pic. I'll probably add a frame in the near future.

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post #18 of 32 Old 02-18-2012, 12:24 AM
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Looks great! Did you "stretch" the BOC like artists do for canvas? When I did mine, stretching it properly was the only way to get rid of wrinkles...

In terms of LFE, size does matter!
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post #19 of 32 Old 02-19-2012, 02:22 PM
 
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Quote:
Originally Posted by Favelle View Post

Looks great! Did you "stretch" the BOC like artists do for canvas? When I did mine, stretching it properly was the only way to get rid of wrinkles...

I found that holding a steam iron about an inch away and waving it across the stretched boc got rid of the folds. Also, putting paint on it will also cause it to stretch out the folds as it dries.
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post #20 of 32 Old 02-23-2012, 01:37 PM - Thread Starter
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Quote:
Originally Posted by Favelle View Post

Looks great! Did you "stretch" the BOC like artists do for canvas? When I did mine, stretching it properly was the only way to get rid of wrinkles...


I pulled as hard as I could till my hands were cramping. The wrinkles came out the next day. No paint needed. If I had to do it again I would try to order some wider boc so that I could go to 120" instead of 110" limited buy the cloth size. 110" is still cool but I'm in a bigger room now and 120" still looked good on the wall without losing pop in eco mode.
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post #21 of 32 Old 02-23-2012, 04:26 PM
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Quote:
Originally Posted by MississippiMan View Post

That sounds "iffy". Why not use a "HangMan"?

http://www.homedepot.com/webapp/wcs/...cStoreNum=8469

....and have no worries whatsoever.

I used this on mine and I love it.

Starting my first HT project!
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post #22 of 32 Old 02-23-2012, 06:16 PM
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Lakersin2025, any pics of how it looks when you have images on the new screen?
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post #23 of 32 Old 02-29-2012, 02:33 PM - Thread Starter
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Quote:
Originally Posted by SchererBoy View Post

Lakersin2025, any pics of how it looks when you have images on the new screen?

Here you go. Don't mind the blurriness, it's just because I didn't pause it and the snowboard action was in full effect. Plus this was taken with my iPhone. You can tell how white and bright the snow looks and this is just in eco mode on my Epson 8130. I can take some nicer ones next movie night if you'd like.

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post #24 of 32 Old 03-05-2012, 05:48 PM
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I just finished my 125" BOC 2.35:1 screen. My frame looks pretty similar to yours, but I added a 3.25" border around the edges with wood trim wrapped in velvet. I highly recommend it, it helps a lot with getting a cleaner edge, and really wasn't all that hard to do.
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post #25 of 32 Old 03-06-2012, 03:40 AM
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It's a well proven fact that the addition of a good Black Border will always improve the perception of Black Levels within the image area. Having one to help frame/the formatted image is just the simplest apparent purpose.

To quote James T. Kirk;
"I'm laughing at the superior intellect"
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post #26 of 32 Old 03-06-2012, 10:20 AM - Thread Starter
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Yea I'm going to make a run to Home Depot one of these days and use the tools and boxes they have in the lumber section to cut the four corners at a 90 degree angle. They only cut them straight for you so I gotta do it by hand since I don't have a table say or box at home.

How much of a gap should I leave to wrap the black felt around the boarder? I was thinking 1/8th of an inch would be about right.
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post #27 of 32 Old 03-06-2012, 12:46 PM
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Quote:
Originally Posted by lakersin2025 View Post

Yea I'm going to make a run to Home Depot one of these days and use the tools and boxes they have in the lumber section to cut the four corners at a 90 degree angle. They only cut them straight for you so I gotta do it by hand since I don't have a table say or box at home.

How much of a gap should I leave to wrap the black felt around the boarder? I was thinking 1/8th of an inch would be about right.

Just take the exact measurement, mark with a line, and cut "on" the line. The saw's blade width will remove just the right amonts of material. When assembling the trim/ends, press the ends together "tightly". The compression renders the "joint" invisible

To quote James T. Kirk;
"I'm laughing at the superior intellect"
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post #28 of 32 Old 03-20-2012, 08:33 AM
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I don't have access to pics ATM, but here's what I did for my black border on my DIY BOC screen (90" diagonal, 16x9).

I built a frame to go around the frame using the same wood (8'x3"'s). I cut the pieces at a 45-degree angle with a mitre box and backsaw (about $15 for the set at HomeDepot). I measured exactly how MississippiMan described. I covered each piece with black velvet first, then attached them around the perimeter of the screen using mending plates/L-plates. Due to each piece being covered first before assembly you cannot see any wood peeking through. While in a bright room you can see a seam where each piece meets, it looks very professional and when the lights are out you see nothing.

One idea I am toying with now is painting the BOC. That idea wasn't even there (AFAIK) back when I built my screen (2004). I may look into it if it would create that much of an improvement.
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post #29 of 32 Old 03-20-2012, 11:36 AM
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I bought 4 8; 2x2's last night in prep to build my screen, but after seeing how well yours came out I think I am going to work with the same wood you did. My 2x2s are slightly warped and have a twist to them...getting them to hold the screen properly without mounting directly to the wall is going to be a problem.

I got the same fabric from Joanns last night on 50% off but am worried about the height as well. Working towards a 106" screen I will only have a half an inch to cover the top and bottom frame. Did you use any tools to try to get it to stretch a bit more?

"Damn, you can't get black levels like that on your projector!"
- My brother, just before he realized his LED display had died.

Link to my Basement build
http://www.avsforum.com/t/1529034/conspiracy-basement-build
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post #30 of 32 Old 03-20-2012, 01:22 PM
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You could buy a pair of canvas pliers, possibly from Joann's, but any art supply store will have them. Imagine a pair of pliers with wide, flat, smooth clips instead of grooved jaws. They look like a binder clip mounted on pliers. Be careful though, as BOC is much more delicate than canvas and will tear! I resisted the temptation to use canvas pliers for that very reason. Building a BOC screen is hard work but it's worth it to do it correctly the first time. Mine is 6 years old and there's not a wrinkle or loose edge on it.
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