Building A Fixed Screen
This guide describes how to build a fixed frame projector screen with wooden beams and a staple gun. This is only an example, and there are many alternative methods available, but the basic principles are the same.
Here at PSM we want to make your project as easy as possible for you. So if you want to just quickly run your plans by us, or want an in-depth discussion regarding your specific needs please dont hesitate to get in contact.
1) Gather supplies
- 1) Staple Gun
- 2) Saw (DIY stores can cut for you)
- 3) Screwdriver
- 4) Tape Measure
- 1) Staples
- 2) Wooden Beams ~ 3" x 1"
- 3) Screws
- 4) L & T-Brackets
- 5) Sand paper
PROTIP: When selecting your wooden beams, choose the straightest pieces you can find, free from twists and knots. Ideally store your beams flat in your projector room for 1-2 days before building your screen, so they can acclimatise.
2) Calculate your frame dimensions
Before purchasing your frame materials, please calculate the height and width of your frame and account for any DeepBlack border you wish to include.
Example If you want a 120” 16:9 screen with a 2” DeepBlack border, please use the following instructions to calculate your frame size:
- 1) Calculate Viewable Size: Using our screen size calculator, input the diagonal length of your desired vieable screen size, for example 120” 16:9 equates to 105” (L) x 59” (H)
- 2) Calculate Frame Size: Add dimensions of DeepBlack border all round to the length and height of the viewable size:
- Frame Length = 105” + 2” + 2” = 109”
- Frame Height = 59” + 2” + 2” = 63”
3) Build your frame
The frame is the foundation to creating a perfectly flat surface to your projector screen.
Cut the wooden beams to correct dimensions. For larger front projection screens, you may want to add internal vertical beams for added support and rigidity.
Join beams together with L & T-Brackets to form the frame. Remove any sharp corners of your wooden frame with sand paper to avoid any possibility of tearing the screen fabric when stretching to your frame.
PROTIP: For any internal vertical beam(s), set these back a couple of millimetres from the front face of the screen so that when you wrap your fabric over the frame, the internal vertical beam(s) do not touch the screen fabric otherwise their presence may telegraph through.
PROTIP: Before making final fixings of your beams, check that the two corner-to-corner diagonal lengths are equal to ensure your frame is perfectly in square. If you find your finished frame is slightly out of square or twisted, don’t worry this can be rectified once you fix it to a flat wall.
4) Attach your screen to the frame
Before unpacking your projector screen material, please ensure your work area is clean and dust free.
Start by laying the projector screen material face down, then place your frame front-side down on top, as shown in the diagram below:
Fold material around frame. We would recommend starting from the centre of one long side and maintain an even tension as you fix a small section. Then fix the opposite side, giving enough tension to pull the fabric taut but not too much that its tearing at your staples, then gradually work towards the corners maintaining an even tension as you go. You may find you have to re-adjust some staple positions as you go.
5) Attach DeepBlack border tape and you done!
DeepBlack border tape can either be applied directly to the screen material or to an external architrave type border.
PROTIP: Don’t overstretch the projector screen border when applying