My current client became the first customer of the new Northern Virginia Home Theater Screen company - Falcon Screens. Those of you who follow the Dedicated Home Theater construction threads may be familiar with the Merrimont Trace project and the builder, Snickers1 (Rich). Instead of just DIYing his own screen he jumped into the fray and invested in a die to make his own aluminum frames and sourced all the other materials to make a competitive AT screen. He promises to have his Web site up later this week to answer questions about his screen.
Like a lot of screens Falcon uses the z-clip mounting brackets. Here they are on a minimalist screen wall frame.
You lay out the frame pieces and put it together.
One feature of his frames, is the Quick Connect corner brackets, they have cam levers that actually pull the frame corners tight together. They slip into channels from the sides and don't have to be pushed in from the ends. This simplifies assembly and locks the corners really tight.
After putting the frame together I pulled out a tape and as Rich held his breath, I measured the diagonals to check if the frame was square. Much to my surprise it was dead on. This hasn't always been the case with other frames I've assembled. I attribute this to the tightening nature of the Quick Connect clips. we added the AT fabric and hung the finished screen. Rich used the o-ring loop and post trampoline system for a quick assembly.
Some more pictures of the project and screen assembly here: