Here's my very first attempt at building a hush box for my Sony VPL-VW695ES projector. It's more of a hush apartment or hush house, but it gets the job done. Also, I have to say, I'm not a handyman by any stretch and this is only my 2nd overall project that I've done (besides my boss mini risers) so it was extremely daunting. The main issue I have is that I want to run my Sony 4k projector on high lamp mode when watching HDR movies, but the fan noise is just too much for me to take. Also, my Sony has both intake and exhaust in the front, so I needed to figure out a way to block all the noise from the front of the projector without restricting proper air flow. So, I sketched up a crazy plan and went to work on it. Also, I wanted to keep costs down, so I just used leftover plywood I had from building my boss mini risers to build the box, used the last of the black paint I had laying around from painting the HT black, and used some leftover styrofoam insulation I had from a project I did for creating panels to block the black bars on my 16x9 screen when watching 2.39:1 aspect ratio films. So, here's a bunch of pics of everything. I tried to list all of the items I purchased but again if I had stuff leftover from other projects that were used, I didn't list them (like screws, paint, rope, etc. I first tried to just put the hush box up on the existing mount I had for the projector, but it was too big and would hang over a few inches, so I bought some hooks and chains and mounted to the ceiling, and that straightened everything right up. As for cooling, the exhaust fans from the projector route air through the duct to the rear (I tilt the duct up at the end of the run) and then the exhaust fans kick it out of the box quite well. All three fans are connected together and run off the single usb connector on the projector.



Links:
https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
https://www.homedepot.com/p/Master-F...-100033952-_-N
https://www.lowes.com/pd/Lambro-4-in...e-Duct/3172543
https://www.homedepot.com/p/Everbilt...6520/203958747
https://www.walmart.com/ip/Ceiling-D...1-pk/121026809
https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
https://www.amazon.com/gp/product/B0...?ie=UTF8&psc=1
https://www.homedepot.com/p/Everbilt...2634/205887675

https://www.edmundoptics.com/p/2032-...y-window/5443/

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Whoa, you gave your projector exhaust pipes, A Very cool and inginuitive design.

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Yeah, it looks like a turbo charger or something!

You might want the lens tunnel all black, or light absorbing. You may be giving up some contrast ratio.

Maybe you are a handyman, just one without a need to build or engineer something in the past?

Thanks for the tip Tedd. I can definitely add in some black velvet to the top and bottom.

Awesome- I have been scouring for ideas for my Epson 5050, Also with front intake and exhaust. Thank you for posting!

Nice job!

I can't tell from the photos, but where does the exhaust air vent to? Is the back of the hush box sealed? If so, where do you obtain fresh air from for the intake air?


I have a very noisy projector (JVC RS4500) and really need a hush box but am concerned about not having the correct amount of air flow into and out of the box.

The back of the hush box is sealed in that it sits flush against the back wall. The top of the hush box has two holes toward the back with two exhaust fans, and the exhaust pipes deliver the hot exhaust directly to those fans above to be removed from the hush box. As for intake, there is a hole in the top of the hush box all the way front and center where there is a fan that delivers air from the room directly above the intake fan of the projector. I have the exhaust and intake far enough apart that it seems to work pretty well. I had considered making the exhaust fan come up from below to further separate the hot air and cool air, but ruled it out because I wanted to reduce the noise as much as possible and having a case fan pointing straight at me would probably not have been a good way to reduce the noise, so I went with the intake on top as well.

Thanks so much for your response. Some more questions:

Where does it exhaust to? The space above the room? How did you determine the size/speed/air flow of the exhaust fan you chose?

If the top of the box is against the ceiling, I'm not sure I understand the room air is pulled into the box. But same question as above: How did you determine he size/speed/air flow of the intake fan you chose? Also, I don't see that you have any temperature sensors in the box to determine if the projector is overheating. The inside of the box overheating is one of the things I worry about. Frying my projector due to some intake or exhaust fan failure is not something I want to think about.

My situation is a bit different in that the projector takes in air from the rear but exhausts from the front. My plan is to build a "front/back separator" in the box to keep the the exhaust air and intake air as separate as possible

I have tall ceilings so the top of the box is actually a good 4 or 5 feet below the ceiling. As for the exhaust fans, I used the AC Infinity 120mm fans that do about 52cfm each at 19db, so for exhaust that gives me 104cfm (could be more if I used the wall outlet but I used the usb connection from the projector), and 52cfm for intake. I run them on the highest setting since they run so quiet. Based on previous experience with building PC's, I felt very confident that these could handle air flow for the hush box so didn't really try to get down to exact measurements. I don't have any temp sensors but that could be a good option for version 2 when I get around to it. For testing, I did run it for a few hours then get up on a ladder and take the top off to see if it was hot inside the box. I didn't notice any problems and also checked to make sure there was no hot air leaking from the connections around the front, and all good as far as I could tell.Hot air was coming out of the exhaust pipes where I wanted it and the exhaust fans were sucking that hot air out of the box and into the room.

Got it. So you pull air in from your room and exhaust the hot air back into the room as well. My plan was to pull the incoming air from my equipment room behind the screen wall (which is cooled by a dedicated mini-Split system) and put the exhaust air into the space above the theater.


Your response has been very helpful. Thanks again.

Yeah, I figured if the projector was intaking and exhausting from the same room and all in the same area (up front) prior to adding the hush box to the mix, this setup would be an improvement to some extent. I didn't want to get crazy with it but surely it would be better to intake from another room and exhaust to another room/area if that is an option for you.