Originally Posted by Ftoast
The two spandex layers will be right on top of each other, touching.
I was digging through gil393's screen thread..it mentioned hand-picked 2x4's for the frame, 2x3's for the supports along with both a kreg jig and internal metal L braces, but I'm not sure what was used in the end.
Gil, would you mind posting a detailed build of your frame?
2 - 2x4x16, 2-2x4x8, 2-2x3x8, 1-4'x8'x3/4"
The 2x4x16's are the key. If you can't find perfectly straight ones at the box score go to a lumber yard and pick some good ones.
My screen is 99" tall. 96" + 2x1.5" top rails. All 2x4 on edge. My width is 176".
Construction was basically butt air nail the top and bottom rails to the stiles while laying on a flat surface, turn over so that the 2x3' short side is facing down (this will be the front of the screen). Square up by taking diagonal measurements. Cut 8 triangular pieces of 3/4" plywood to brace all joints, using air nailer. Hang via 3/4 pine french cleat.
After a year or so I have a very slight warp on the diagonal which is easily controlled via hook and eye bolts on the bottom edge pulling it flush to the wall.
I installed the spandex from the top, starting in the top center and working across and outward as per the various instructions in this forum. I simply air stapled to the flat side/edge of the 2x4. Not as neat and clean as working from the back side and stapling into the back of the rail. My thought was that at 4.25" thick the screen was not really invisible and the low end workmanship didn't matter much. It can always be covered with a black velvet or such if desired.
Voila, one big, cheap screen.