No, I've not "given up" this DIY project, other normal life distractions got in the way for a while.
Plus, like others here have found out, the temp primer drywall'd wall screen does a decent enough job so we've been watching that and the "pressure" to finish the "real" screen is less.
Since I want to carpet the HT room over xmas vacation all these little/final DIY projects now have to get done.
Therefore, finally made some progress over Thanksgiving weekend (Sat afternoon and Sunday).
Wood frame making that will become curved and used for attaching DW laminate & screen black border too.
I used base board molding from HomeDepot, it was 1/2" thick x 4" wide, mostly flat with slight router shape on the top edge.
Used table saw to get rid of that for a 3 1/2" wide piece.
The whole wood frame will be mostly overhang the alum frame by 1/4" on the inside and the rest overhang on the outside.
Measure/cut confirm before attaching together.
Wood frame together, used dual corner braces to keep the frame "flat/in plane to itself" when it becomes curved:
(that's my theory at least...)
Getting ready to attach the wood frame to the alum frame.
The alum frame is blocked off ground at the 4 corners and center.
Corner shot and misc hardware to be used:
After debating/different design concepts for the end supports, I decided to use 4 x 4 (really 3 1/2 x 3 1/4) Cedar post. I picked a very tight grain running the correct direction for my mounting.
Using geometry/trig 101, and wiki http://en.wikipedia.org/wiki/Circular_segment
, calculated the correct angle.
Notched them for nesting onto the alum frame and attachment method.
This pict shows 6 "identical" blocks that are cut at @ 7.11 degrees, height of 3.67", 3 used per side.
Missed taking some in process shots.
Basically aligned wood frame over alum frame, with 1/4" overhang all round on inside.
Clamped at 4 corners.
Attach at middle.
Attach at mid support. I used same cedar stock, calc correct angle.
Here shows with 1st end support in place roughly during confirm fitting.
Ended up using 2" decking screws to attach the cedar block to the alum frame and also the wood frame to the cedar block.
All mtg screws on wood frame are sunk just below surface for flush DW laminate mtg.
A composite alum/wood frame curve screen in process.
The small block was cut at 3.55 deg with a height of 0.914"
Nothing like some background AC/DC while working...
Stay tuned, I'll be working on this nightly.
I'm going to get the mounting done next and mount w/o screen.
There will be a border frame attached on top of the wood frame once it is laminated.