Join Date: Mar 2001
Location: Edmonton, AB, Can
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Today I picked up the material to build my own screen. From Fabricland I picked 3 yards of 'blackout' fabric, 54" wide, and some matte black cloth. Then I went to Home Depot and picked up two 8' fir 1 x 4's, two 6' fir 1 x 4's, and a couple of fir 1 x 2's. I also bought some metal angles for tying the corners together.
My original plan was to cut and mitre the wood to make a frame with interior dimensions of 92 x 52, then staple the black matte cloth around the frame members, so you wind up with a hollow black rectangle. Then the blackout material would be stapled to the back of the frame, so that when it's hung on the wall the cloth would be between the wall and the frame, and you'd be looking through the frame at the screen, with the frame acting as a fixed mask.
Now, the problem is that this setup doesn't allow you to put supports in the middle of the frame, and I have my doubts about the rigidity of this.
The other option is to wrap the screen fabric around the front of of the frame and staple it in back, like an artist's canvas. But then masking becomes a problem. How do you do a neat job of adding the black fabric around the edges?
The third option would be to build the frame and build an inner frame in that with the supports. Put the fabric on the ground face down, put the small frame on the back of it, Pull the cloth tight and staple, then fit the big frame with the black cloth around that whole assembly.
Any thoughts or hints on the best way to build this thing?
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