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How big does it have to be? I built a cheap screen for outdoor use using blackout cloth and 1" PVC pipe. Gives me a 110" 16:9 image. Would have been nice to go bigger, but that was the biggest the blackout cloth would allow unless I wanted seams. All materials cost me less than $30.
 

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I did a little bit of research this past weekend on this, and it seems that the biggest you can really get with blackout cloth (from JoAnn Fabrics) is 110" diagonal.


I wanted to go bigger then this, and it looks like people have had pretty good results with a painters drop cloth. You can get 12'x9' for under 20 bucks at Home Depot, and this should be able to support ~165" 16X9
 

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Carl's Place sells blackout cloth that is 110" wide and as long as you want. You could get a seamless 16'x9' screen with his material. Also sells it finished (black border and grommets) for a little more.
 
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