Thought I would copy this over here from my built thread as this is the root of my inspiration for going the DIY spandex way and where builds seam to congregate
DIY 124" Spandex Screen
Total Cost ~$270CAD
Frame made out of 1x4 Choice Fir placed on edge with a stiffening piece wrapping the outside edge. Joinery using a Kreg jig, brads and glue. All edges where screen meets wood was sanded to avoid snags
Screen material is white over black spandex held on with screen tight and spline
I decided on Fir as it was the most reasonably price "hardwood" that was deadly straight in the store (Timbermart). Spruce, polar and pine are infamously bad for being warped in some shape or form up here. Oak was double the price.
Frame on edge..... because my screen is floating off the wall I did not want it to be to thick by going with the wood on the flat. However, I also did not want it to be to easily warped or bent...... thus the outer stiffener
Spandex is a great alternative to the manufactured systems and has an excellent picture. I was able to see a grey over black screen in action with the same Epson 5030 projector that I have. Thanks
I chose White over Black to try and get the white levels a little better than the grey but trying to maintain the blacks.... I think this has been achieved nicely.
The addition of this to the outer edge increased the rigidity of the frame. To make this piece I ripped the board to 1 1/2" wide. dadoed out the groove on my table saw and cut back the one side a ~10 degrees to minimize the wood in contact with the spandex. Attached around the outer edge with glue and brads.
The location of the dado is also strategic in that it alows for the screen tigh to be fully hidden from the side. This worked like a dream
Painted black.... not sure if this was needed but hey I had some..... I can not see the frame at all through spandex
Mounting was done with three "L" shaped brackets screwed to the wall framing..... placed so the screen frame fits snugly in place with a minor smack of the fist. I might adjust this at a later date as it is maybe a little to tight with the fabric on now.... TBD
The vertical piece is 1/8" thick to it does not come in contact with the screen.... lots of pre figuring with the stiffener
Side shot.... yes there is screen tight hiding back there
The black going on
The White.... getting the corners on this layer was much more difficult..... probably cause I was not as concerned with the uniformity of the black layer as the white. getting the stretch right in the corners took a few tries but we got it. I also think the further distance to the second track and as a result more fabric to deal with was a major factor in the difficulty
Finished product, one day I will be installing LED lighting behind screen to cast onto the rock