Yes, still here. Just been busy.
Now that I have the trim worked out, I can take some pictures and start uploading them. I had my upholstery guy attach the velveteen to the MDF. Turns out that he's much better at it than I am. I guess I'll stick to the engineering.
I have been using the screen in 16x9 mode, simply because my A lens is not up. But, I can say that it has been quite a pleasant experience none-the-less.
I'm using a "proprietary" 1x gain screen material (non AT). Looks good with my Panny. The screen frame can accept any screen material, AT or non-AT.