Projector box for Epson 5040 - AVS Forum | Home Theater Discussions And Reviews
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post #1 of 23 Old 04-14-2019, 04:57 PM - Thread Starter
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Projector box for Epson 5040

I need to build a box for my out of the wall projection needs. Was going to build a black 21"w x 7.5"h x 21" deep for it. It appears the intake and exhaust are both on the front of this unit so I think I'm ok with cooling but wanted to get some additional insight on this plan to make sure I don't burn up this projector. I was going to also enclose the back except for a small access area for the hdmi and power cables. Thoughts?
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post #2 of 23 Old 04-14-2019, 05:06 PM
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so the front of the box is open? what are you lining the box with?
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post #3 of 23 Old 04-14-2019, 05:15 PM - Thread Starter
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Yes the entire front of the box will be open. I was going to build it out of furniture grade plywood and paint it black on the inside. It extends into a air conditioned closet space where 2 of my air handlers are located. To keep the noise down from the older unit, I was going to wrap the box with some r30. Open for ideas. Originally was going to hang the projector but the wife's barn door has pushed the projector into the wall.
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post #4 of 23 Old 04-14-2019, 05:41 PM
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so basically you are building this around your projector:



My experience is that open front projector boxes need to be lined with sound absorbing materials otherwise they focus projector noise directly at the seating area.

I also see you are planning on removing the feet on the projector so it will fit in your very tight box (1/4 inch gap on each side, 3/4 inch on the top without the feet) , that may increase the transfer of fan vibration noise. I'm not sure of the feet design on that projector and whether it includes any resilient material. I wouldn't build the box as tight as you are proposing, build it big enough for at least one inch of absorbing all around and some room for air movement, even if the intake and exhaust are on the front. The projector case itself will get warm.
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post #5 of 23 Old 04-14-2019, 06:06 PM - Thread Starter
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Great insight I didn't consider. Can I line the box with that black AC duct material? All 5 sides and let he projector sit on that material? What kind of clearance on the sides and top and back do you recommend between the projector and the AC duct material? The feet are a hard plastic. I'm going to have some decent bass in this theater, also wondering how this projector will fare in deep bass. It appears to have a narrow 2" wide rubber foot built into the rear with the two hard plastic adjustable feet up front. Thanks again for the help here.
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post #6 of 23 Old 04-14-2019, 07:23 PM
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yes black duct liner is perfect. You can probably skip under the projector. I would leave a couple of inches breathing room to the sides and above.
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post #7 of 23 Old 04-19-2019, 07:19 AM
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Following advice from BIG, I used scrap OC 703 and scrap fabric from my theater build to help with my PJ noise isolation. Also used pyramid style 1’ sound panels as well.










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post #8 of 23 Old 04-19-2019, 07:33 AM - Thread Starter
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Why would you not just use the black duct board that has the black fabric felt built in? This job looks a little wonky up close at least. Maybe it's not noticeable far away!!
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post #9 of 23 Old 04-19-2019, 07:37 AM - Thread Starter
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BigMouthIn - I was going to use 1/2" ply for the box and I assume 1" duct board. What kind of glue do you use to glue the duct board shiny side to the plywood?
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post #10 of 23 Old 04-19-2019, 07:44 AM
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Projector box for Epson 5040

Quote:
Originally Posted by acribb View Post
Why would you not just use the black duct board that has the black fabric felt built in? This job looks a little wonky up close at least. Maybe it's not noticeable far away!!


I had extra material and Did not want to spend more $$$. No one will have their head up in the projector box analyzing the fine details . Just wanted to share as a reference.





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post #11 of 23 Old 04-19-2019, 08:09 AM
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Quote:
Originally Posted by Oklahomie View Post
I had extra material and Did not want to spend more $$$. No one will have their head up in the projector box analyzing the fine details . Just wanted to share as a reference.
Yeah that projector is a beast. Nobody's seeing behind that haha.

Also Oklahomie - you should update your sig with a link to your build thread so more people can see it, in case they miss it in the main area!

Ashton Cove Theater

Also you should submit it for home theater of the month asap as well
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post #12 of 23 Old 04-19-2019, 11:01 AM - Thread Starter
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Quote:
Originally Posted by Oklahomie View Post
I had extra material and Did not want to spend more $$$. No one will have their head up in the projector box analyzing the fine details . Just wanted to share as a reference.





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Can I take back what I said Oklahomie? Looks fantastic! Sorry, I saw cardboard clips and prematurely passed judgement. My ceilings are only 8 feet so you would definitely see those cardboard rings in my setting.
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post #13 of 23 Old 04-19-2019, 01:13 PM
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Aaron has a great theater and cool box for some ideas. Feel free to check out my The Force Theater thread as well as there is definite variation there, but might give an idea about the bigger box like BIG was eluding to.
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post #14 of 23 Old 04-19-2019, 01:29 PM
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Quote:
Originally Posted by acribb View Post
Can I take back what I said Oklahomie? Looks fantastic! Sorry, I saw cardboard clips and prematurely passed judgement. My ceilings are only 8 feet so you would definitely see those cardboard rings in my setting.


I just didn’t paint them or cover them in fabric, but the duct liner would be perfect as well. Jedi’s is very nice, too. Check that out for another perspective.


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post #15 of 23 Old 04-20-2019, 08:30 AM - Thread Starter
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Quote:
Originally Posted by jedi1982 View Post
Aaron has a great theater and cool box for some ideas. Feel free to check out my The Force Theater thread as well as there is definite variation there, but might give an idea about the bigger box like BIG was eluding to.
What page in your Force Theater thread has the projector box build in it? 🙂
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post #16 of 23 Old 04-20-2019, 08:52 AM
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Quote:
Originally Posted by acribb View Post
What page in your Force Theater thread has the projector box build in it? 🙂
There's not any detailed pics of the actual box build but can give you an idea of what is in there though starting on page 6. Left enough room like BIG was talking about for air circulation knowing would have the front of the box mostly covered up (black plexiglass). Inside, I have a 120mm exhaust fan (uber quiet and on front side of soffit) that kicks on at 85 degrees and sucks the hot air out the top of the box and spits it directly into the return vent as the fan is connected via flex tubing to the return. There are no good pics of that but you can see in the pics that the front 1/2 of the box has more room as that part isn't built into the soffit. The back 1/2 of the box is build around the soffit and the inside is lower. Most of the inside is lined with Linacoustic as well.

My best recommendation would be to contract with BIG for a few consulting hours as I did throughout the entire project to make sure what I'm doing will be best for what I'm trying to accomplish!
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post #17 of 23 Old 04-20-2019, 02:24 PM - Thread Starter
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Do you think I need to line the Bottom of the box with Linacoustic or will sides, top and back suffice? What glue do I use to glue the Linacoustic to the plywood box?
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post #18 of 23 Old 04-21-2019, 05:54 AM
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you wouldn't want it under the feet but if there are open areas, yes. The coated side should face the open box area, not the sides of the box.

3M spray adhesive. You can also use a few drywall screws to hold the Linacoustic in position. Put the top in first then friction fit the sides to hold it up by the edges.


Last edited by BIGmouthinDC; 04-21-2019 at 05:58 AM.
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post #19 of 23 Old 04-21-2019, 06:33 AM - Thread Starter
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Jeff, what do you mean by"the coated side should face the open box area"? I was planning on covering up the edges of the 1/2" ply wood box and the 1" duct liner with 1 3/4" trim that matches the room but I'm down with other ideas. Thoughts?
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post #20 of 23 Old 04-21-2019, 06:45 AM
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the coated side mitigates fibers becoming airborne, many first time users think the soft side will absorb sound better and place it facing the room, don't do that.
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post #21 of 23 Old 04-21-2019, 07:57 AM - Thread Starter
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I was going to use duct BOARD rather than lining since it sounded easier to handle. https://www.budgetheating.com/Duct-b...CABEgK68PD_BwE

Duct LINER is preferred?
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post #22 of 23 Old 04-21-2019, 08:40 AM
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The NRC data of one inch duct board is similar to one inch Linacoustic.
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post #23 of 23 Old 04-22-2019, 09:17 AM
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I have an Epson 5040 and here's the box I built. I lined it with the cheaper acoustic foam. You do hear fan noise but with the fans blowing air out the front I don't know how much you can really muffle the sound without hindering airflow. If you can build it on a rollout shelf. This has come in handy a whole bunch when trying to get to the projector and not needed to re-align anything afterwards :






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