Watching a movie or playing a game on a large 100-inch screen can be a new experience made possible thanks to the technology of front projection setups. A home theater screen offers you a picture that's brighter and more vivid than projecting the picture onto a blank wall. With a few steps you can create a screen that rivals retail offerings at a fraction of the price, and in the process gain the fullest home theater experience possible.
Frame Construction
Choose the materials for your frame construction that will go along nicely with your viewing room. Simple frames can be made from plywood covered in black cloth to prevent reflected light from your projector. Go with a semi-hard wood like fir for a nicer frame look. The right wood for your frame is one that is easily finished to complement your existing decor.
Create a frame to the size you're planning to project. You'll want to use your projector to project a test image onto the wall which you're intending on mounting your screen to prior to making that first wood cut in order to know precisely what dimensions you're going for.
Use 1/4in. strips for your frame edges, cut to the desired size. Attach 3/4in. shelving material to the rear of the frame for bracing. Glue the frame together then use a series of staples to firm up the frame's construction. For ease of installation of your completed screen cut a few handholds into the frame for moving it around.
Fabric Surfaces
There are two primary surfaces useful for a DIY home theater screen. The first is a fabric surface stretched tightly across the frame. This is an inexpensive method of creating a projector surface moderately better than an untreated wall. Choose a plain white blackout fabric for the simple stretched screen. This is the type of fabric generally used to back curtains to prevent light from passing through, and can be found at most fabric stores.
Fold the fabric over a side of your frame and tack it to the center of the frame's side. Place the tacked edge onto a flat surface, then stretch the fabric over the frame until you see a crease in the fabric showing that the fit is a taunt one. Tack the opposite edge of the fabric. Repeat the process for the remaining sides until the creases running between tacks form a diamond shape.
Use a staple gun to attach the fabric firmly into place, working outward from the tacks and moving the crease along as you progress. When you reach the corners, tuck a side of the fabric over, then fold and staple the corner piece. That's it for the stretched fabric screen, place a few eye hooks on the rear of the frame then mount it to your wall.
Painted Surfaces
The second surface method is a bit more work and can be more decorative as well. It also provides a better image quality. This method requires that you prepare and paint a surface to which you will mount your frame. Unlike the stretched fabric method, the frame will be visible, so you'll need to cover it with black non-reflective material or varnish it to match the decor.
Prepare a flat featureless surface to act as your screen. If you're using your wall you'll need to sand it smooth, otherwise a piece of sheetrock or wallboard from a hardware store will do as a surface. Prime the surface with an alkyd-based primer, sanding away any imperfections when it dries. Next apply the screen paint.
Choose paint that you're comfortable with. There are several to pick from but the best to use are Goo System's Screen Goo in the Digital Grey color, Behr Silver Screen spray paint, or DIY Black Widow mixture consisting of an aluminum gray paint to a beige flat enamel in a 1-to-4 ratio. Any of those choices will give you a projector surface that brings out both color and shadows. Once the surface has dried, mount the frame, and your screen is complete and ready for viewing.
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