I don’t know if this would be of interest to anyone here or not, but I found an inexpensive solution that so far I am pretty happy with.
I bought an Optoma UHD50 4K DLP projector in December. I am very pleased with its image. Because of its shorter throw I am getting an approximate 96” wide letterboxed image on my 1.78:1 screen. This is great for wide screen movies (bigger IS better) but using its 3:1 zoom lens I prefer to zoom down to its smallest image for 1.85:1 movies.
The next thing I tried was that using the projector’s modest vertical adjustment I found I could run the image up high enough to mask the top letter box bar. This worked great, but of course made for an even taller gray bar at the bottom of the image. So next I tried holding out a yardstick horizontally to see if I could get a clean enough masking of the bottom letter box bar. It worked.
So I got a slender piece of wood about four foot wide and suspended it horizontally from my ceiling with metal chains. Then I draped pieces of black cloth from the wood. This worked! But only because I have to sit off axis of the projector’s beam because of where the projector had to be placed so I wasn’t blocking its image. This seating arrangement also necessitated adjusting speaker levels in my receiver to balance the sound.
This setup admittedly looks peculiar, but doesn’t bother me because this is a one man movie theater in a small bedroom in our mobile home. My wife prefers watching tv and movies on our 65” tv in our living room. When NOT watching Wide screen film, I simply remove the barrier and go back to watching a smaller image.
If I get tired of this setup, I may try building a very light frame to mask the oversized bottom letter box bar on the bottom of the screen, and then staple black cloth to the front of it. This WOULD make it easier for me to seat myself for a movie!