Thanks for the compliments!
Ok, so the 2xs are not "flush" to the curve, they create the curve that a 1x4 follows. I have a 1x4 frame that is screwed to 90 degree angle brackets that are screwed into the 2x "studs". The studs create the curve as I figured this would be much easier than trying to jigsaw a perfect arc. Left to Right the studs go: One 2x6, One 2x4, One 2x3, One 2x4 in the center that is staggered back so that its actually like a 2x1 3/4 or something like that, then One 2x3, One 2x4, One 2x6. All of the studs, with the exception of the center start with their "backs" on the same line, this way they "step in" on the front and create a curve for the 1x4 frame to follow. My velvet wrapped border is a 1x8, it is also what the screen attaches to. The velvet frame attaches to the 1x4 frame via screws in the back going from the backside of the 1x4, through the 1x4, then partially through the 1x8 but not all the way through the 1x8 because you don't want screw tips poking through your velvet and sticking out the face of your screen's border. Since it is screwed to the 1x4, it adopts the same curve. My screen's material is the Seymour XD, I asked Chris to add grommets to the material pre-shipment, an option that costs more but worth the price IMO. My screen is attached to the velvet border using D-rings attached to O-rings, the O-rings go through the grommet holes and then hook onto picture frame hooks that I placed on the backside of the velvet border. The D-rings are larger than the grommet holes so they don't get pulled through. Since the screen is attached to the picture hooks that are attached to the velvet border that is attached to the 1x4 frame that is attached to the studs, the screen adopts the curve as well and the tension of the O-rings holds everything tight. I know this sounds complicated, but its really extremely simple and I'm still not sure why nobody else builds them this way.