AT curved scope build - AVS Forum
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post #1 of 18 Old 01-04-2014, 09:11 AM - Thread Starter
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OK...I am early in the process and have been encouraged to start the thread now...so perhaps this will be of use/enjoyment for others.

I'll give some background.

Current theater was completed about 6 years ago. It is approx13' wide by16 and change deep.

I recently took down a marquee 9500lc CRT projector that served me well for those years and decided the market in digital projectors was ready for me wink.gif

A few years ago I grabbed a b stock panamorph uh 480...and have always been looking forward to a day where I could use it for

More in a bit...
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post #2 of 18 Old 01-07-2014, 06:14 AM
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Quote:
Originally Posted by armstrr View Post

OK...I am early in the process and have been encouraged to start the thread now...so perhaps this will be of use/enjoyment for others.

I'll give some background.

Current theater was completed about 6 years ago. It is approx13' wide by16 and change deep.

I recently took down a marquee 9500lc CRT projector that served me well for those years and decided the market in digital projectors was ready for me wink.gif

A few years ago I grabbed a b stock panamorph uh 480...and have always been looking forward to a day where I could use it for

More in a bit...

I may be building the same. I'm interested in a curved masking system for a 130" diagonal 2.35 that I can mask for 16:9 and 4:3 too. My objective would be to have the masking system to completely close . I may even consider
a flat screen and multipul masking formats as well.

I have a Sony 600ES and also have the UH480 btw.
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post #3 of 18 Old 01-07-2014, 07:44 AM - Thread Starter
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I had some falcon screen AT material delivered and have begun the the build. I purchased 12' 2x8 and 2x4 lumber. I clamped the lumber together and let it sit for a week in the hope the lumber would acclimatize to the humidity and remain fairly stable.

Based on Aussiebob's calculator (props to him!) I came up with a 35.8' radius. My prefference would be to set up a trammel and physically mark the curve...and were it summer, that's how it would have been done. given this weeks temps of -40 deg C (with wind chill)...no screen is worth that, so i embarked on mathematically calculating the depth of the curve from the chord. A lot of googling, some help from some forum members and a couple friends (thanks Tosh's!!!), I got a formula and was able to build a chart, and then check it by graphing it. it worked! Even if you have never used the metric system, it may be worth trying it since working to the nearest mm is easier than calculating fractions of inches...and AB's excel spreadsheet allows you to input both metric and imperial units, so you can go between them at your convienience.

I printed depths for 5cm and 1cm increments from the center point...just in case. I ended up finding the 5cm increments enough. I then cut a strip of wood approx 1/4" by 11/4" x 11' and drove screws about every 20 cm used the wood to mark the curve...see pics below.

my plan is to cut out the curve and then attach a piece of lumber vertically to the curve that will act as the masking and and serve to stiffen the structure and lessen the chance to flex. I plan to rip the 2x4 on a tablesaw to the correct dimentions...likely 1/2" thick. the masking can only be 2 2/4" wide as that will yeild just enough room to slide my subs under the screen frame as i only have 82" height due to duct work, and the subs (laying on their sides...) are 22 1/4" high.

i purchased o-rings from amazon as well as a grommet kit and refils. My plan is to fold the falcon screen material over duct tape or a fabric stifening tape...(not sure what its called...and grommet through the tape and doubled over material. screws or bolts placed around the edge will act as anchor points for the o rings to tension the screen. this method of screen building and tensioning has been borrowed from some other screen builds.
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post #4 of 18 Old 01-07-2014, 08:18 AM - Thread Starter
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post #5 of 18 Old 01-08-2014, 05:18 AM
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Reminds me of the DIY Torus screens, back in the crt days. smile.gif
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post #6 of 18 Old 01-08-2014, 06:07 AM - Thread Starter
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Reminds me of the DIY Torus screens, back in the crt days. smile.gif
but this time I'm using math!
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post #7 of 18 Old 01-11-2014, 01:33 PM - Thread Starter
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post #8 of 18 Old 02-26-2014, 03:53 PM - Thread Starter
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post #9 of 18 Old 02-27-2014, 11:36 PM
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Looks great, man. Glad to see a fellow Canuck doing a curved screen. I built one myself and it's the bees knees around here. I initially used spandex but I ended up switching it out and went with Seymour Centerstage XD material and it's been fantastic. I'm looking forward to seeing how it all turns out for you. Best of luck.

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post #10 of 18 Old 02-28-2014, 09:31 PM - Thread Starter
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Painted

Installed turnbuckle and eyebolts to bring it back dead straight since the main horizontal frame bowed in toward the cut

Drilled and glued in neodymium magnuts to hold masking panels
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post #11 of 18 Old 03-01-2014, 11:09 AM - Thread Starter
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A little Royalty 3 velvet (not to be confused with Royalty 1 or 2!)
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post #12 of 18 Old 03-03-2014, 05:05 PM - Thread Starter
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Final size: 127 x 53- (137 ³/⁴" diagonal)
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post #13 of 18 Old 03-20-2014, 07:33 PM - Thread Starter
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post #14 of 18 Old 03-20-2014, 07:34 PM - Thread Starter
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The money shot... (Quick and dirty alignment...no calibration)

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post #15 of 18 Old 03-31-2014, 05:13 PM - Thread Starter
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I Started the masking panels. Simple 1/4" hardboard with magnets mounted to match the screen. Cut outs made to save weight. Corners rounded to better accept the velvet that will be glued on.

The magnets are spaced such that I can slide them over for 1.85 movies if I choose... The bit I used gave a very snug fit, so I drilled through flushed the magnets up and then mixed up epoxy and filled in the backside.

The clamps are holding a 3/8" thick strip of pine to the inside edge. This will keep the panels from bowing and take up the gap that would otherwise be about a 1/2"







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post #16 of 18 Old 03-31-2014, 05:51 PM
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+100 biggrin.gif
Awesome job, hopefully others will see DIY can be fun, save $, and satisfaction.
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post #17 of 18 Old 03-31-2014, 07:25 PM
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Great Work looks awseome can't wait to see some final pics.
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post #18 of 18 Old 04-07-2014, 08:29 AM - Thread Starter
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Anyone who has debated the merits of black velvet...it may be the biggest improvement 200 bucks can bring to a projector install. I built some light framing by ripping some 3/4" ply into 1 3/4" strips. The Kreg jig may be the best thing since sliced bread for building.these...each panel took about 20min to build. Friction fit and a few strategicly placed magnets hold everything in check Joannes 50% off coupon helped with the 23 yards I ordered...approx 3000 staples later...

















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