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Scavenging a cheapo motorized model for DIY acoustically transparent screen?

post #1 of 10
Thread Starter 
I've recently started looking into building a projection screen on my own; the reason being, I haven't been able to find a screen that meets all my criteria:
  • No wider than 70" (80"-ish diagonal)
  • Acoustically transparent (AT)
  • Shouldn't cause moire at that full projection size with a 1080p image (or, ideally, even with smaller 1080p images)
  • Must not have a pattern that will be visible to me from 9 feet (which incidentally implies "no perforated vinyl", because their patterns are too coarse; so, "woven fabric only!")
  • Motorized, or at least "rollable/part-time" (for on-ceiling mounting)
  • Black backing that is also acoustically transparent
  • Cheaper than a reasonable secondhand car (i.e., "no Screen Research")

My latest idea is to experiment with getting a (reasonably) cheapo motorized non-AT screen, taking out its original screen material, and attaching to it some home-made AT fabric (as simple as linen?) and black AT backing material (black speaker grill cloth, or any black fabric?). Anyway, the actual materials that I could try will vary, but I'm basically planning to lowball the fabric selection (at least initially).

I've done my homework and looked through all the FAQs and stickies on this forum, but the only direct mention of buying a cheap motorized screen to replace its material with something custom was in a single thread, and the discussion there didn't elaborate much on the process of the replacement itself. So, I decided I'll start this new thread to see if I could gather some first-hand feedback on specifically this aspect of such an attempt:

What do you think about the difficulty/feasibility of replacing the material of a purchased cheap motorized projection screen?

Specifically, are there any caveats or any "musts"? Any tricks to avoid bunching or waviness? Did you (or should I) remove the whole screen surface down to the rotating tube and reattach the material directly onto it, or should I plan to cut-and-sew somewhere midway for better results? Any specific kind of cheapo screen I should look for, which might make the transplantation more convenient or more manageable?

Further, (and I really expect even less first-hand feedback to be available on this) what was your black AT backing material, assuming it was successful? For that matter, what was your primary screen material, assuming it ended up moire-free and with unnoticeable fabric pattern at such low viewing distances and image sizes as my requirements, and with 1080p images and assuming strong 20:20 eye sight?

(That is quite a set of specialized questions, isn't it? I know. I think I'm about to "niche myself" to oblivion soon...)
post #2 of 10
your best thread to follow that has most of your answers (I think) is the diy your self motorized screen by bulldog... since he goes thru most of the steps for attaching material for an AT screen which is his target. Even though he uses his "own" tube, in essence so are you... just "specially manufactured" for screens ... :-)
post #3 of 10
Thread Starter 
I guess you're right.

Actually, I did look through that thread. But, now that I can't gather any more specific feedback, I suppose I'll go back and go through it a with a fine-toothed comb...

Thanks.
post #4 of 10
I didn't mean to "throw water" on your thread... just wanted to point out the other one. Hopefully, you will get some input as requested. My "2 cents" based on my DIY electric experience using a car window motor and "re-enforced" cardboard fabric tubes is that your idea is "straight forward". If you can get some woven fiberglass based material (smx or others), then your chances of reduced wave problems will be great. Your "just a linen sheet" idea is not going to work as the material doesn't have enough "body" and will not roll up "predictably". I attached my BO cloth and vinyl based screen to the "roller" using simple masking tape. If you keep a few turns of material on the roller at all times, you won't need much to hold it in place. Manufacturer screens use some form of adhesive (hot melt????). The key is to get the transition as smooth as possible as it will leave an imprint on subsequent layers of the wrap and eventual show up on your screen in the view area as regular spaced lines. Of course, the other consideration is to mount the material "totally" aligned with the roller so that it will roll up without creeping to the left or right. Good luck. Your project is doable as long as your expectations are not really really high... shoot for 75%.
post #5 of 10
Thread Starter 
I appreciate the suggestions. That's helpful.

Not having attempted this before, any specifics on the details helps a lot, at this stage. I have other questions in my mind, too. Such as what to do with the (vertical) edges of the screen material. Leave them raw cut? Fold them over and stitch? Tape? The same goes for attaching the "weighting bar" (?) (not up to speed on my detail terminology) along the bottom edge of the screen. Should I loop the material around it and stitch? What kind of stitching anyway? Not by hand, certainly. I don't have sewing machine either. So, taping again, maybe?

Other questions revolve around the black AT backing. I get the impression that even fewer people around here utilize something like that. There are many uncertainties in my mind about attaching that to the screen material. I also wonder whether it might interact with the screen material and cause additional waving or bunching (when rolled up, perhaps).

Not that I expect to hear answers to all of these. I'm mostly just conveying my stream of thoughts...
post #6 of 10
As far as edges are concerned... it depends I guess. On my BO cloth screen, I sewed (actaully my wife sewed) black vinyl around as a border since I didn't want to try my hand at painting... since this was my first "venture" into screening. The problem with adding material to existing material is that you change the thickness and as a result, impact the "rollability" which can cause problems like waves and wrinkles. BO cloth doesn't have much body so it was a problem but woven / fiberbglass based material might have more "integrity" and may be less impacted. You will probably have to experiment a bit.... buy extra material...:-)

As far as a lower rail, I "sandwiched" the lower screen (vinyl) between to 1X2 in pieces of hardwood that were held together with screws along the length... this design is similar to production screens which use aluminum channelling. As you have indicated, some have gone the "loop" method which is probably just as successful.

As far as stitching, my wife used a "normal" sewing machine with "normal stitching".... kind of like this "=========" which is just a single stitch run twice. I used masking tape just outside the stitching to hold the two materials thru the machine along with a long hall and some spare cardboard fabric tubes to hold the excess material as it goes thru the machine. It was pretty straight forward once all the "arguing" is done on "how to best accomplish the job"... :-)

Since you don't have a machine, I would go with the "sandwich mode" on the bottom rail. I would go with painting for borders or go bordless.

As for backing, I don't know.... but maybe someone will pipe in. Rolling up two types of material may be difficult to impossible based on my limited experience.... again some experimenting will probably yield you with some great knowledge... for a "second career"... :-)
post #7 of 10
Thread Starter 
Those are some very helpful specifics. Thank you very much.

The backing is still the biggest question mark in my mind. Apparently, for good reason... I guess it will all come down to just experimenting on my own, like you said.

Thanks again!
post #8 of 10
In terms of your backing, you might want to consider accommodating the backing on a separate roller system behind the screen that can be rolled down independently.
post #9 of 10
Thread Starter 
Quote:
Originally Posted by budwich View Post

In terms of your backing, you might want to consider accommodating the backing on a separate roller system behind the screen that can be rolled down independently.

That might make things simpler on the technical side, but I don't know how it will sit with my girlfriend if I attempt to drill that many things onto the ceiling of our apartment's living room...
post #10 of 10
Quote:
Originally Posted by budwich View Post

It was pretty straight forward once all the "arguing" is done on "how to best accomplish the job"... :-)

LOL... describes my house to a "T".

I'll watch this thread going forward as I'm headed down the same path after reading Bulldogger's thread.

Good luck and keep us posted...
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