Hi,I found this discussion while I was searching for information and or reviews on the ALR material from Carl's Place. Coincidentally, I have the Epson 2040 as well. The idea of making my own screen (with the help of my handyman - I do not have the tools to do it right) has given me the chance to look at different materials to construct the frame. Wooden frame is the first one that comes to my mind, with the slight doubt whether it will stay straight without any obvious warps along the length. It's hard to find any aluminum framing material, so I came up with an idea for a composite design with a 1"x3" wooden frame kept straight by attaching a 1 inch square aluminum tube screwed on the back side of the wooden frame.
After comparing the different sample materials I received from Carl's Place, it wasn't too difficult to select the best material - I have narrowed down on the ALR!
Thank you for sharing your views and opinions and your step by step decision making on the selection of screen materials, etc.
I'm trying to get a thin black border for the edge, by using a 3/4" aluminum U channel covered with black felt border tape (also available from Carl's Place). That would require the outside edge of the frame to be cut down to less than 3/4" with a router.