How to Build a Video Projection Screen

by: Andrew Seltz

You have chosen to purchase or build a video projector as the foundation of your home theater system. This decision gives you a lot of flexibility when designing your theater. You are not locked into the preset image sizes offered by television manufacturers. You can project the image to fill the space you have available and create a true theater experience.

To get the best image from your projector you will need to use a screen. In this article we will focus on creating a fixed screen optimized to deliver the highest quality image possible.

Projecting onto a plain wall will compromise your image. Wall paint is designed to cover and color your walls. The quality of the pigments and binders that make up the paint is a balance between cost and quality with little consideration given to the precise nature in which it reflects light. Far more thought is given to whether it is washable.

Several special wall paints are available which are designed and manufactured to provide a projection surface for your home theater. They are more expensive than a typical gallon of paint and will require a bit more care during application, but the results are excellent.

Tools and Supplies You Will Need:

• Hammer Miter Saw or Miter Box and Handsaw
• Paint Roller or Paint Sprayer
• Paint Roller Pan
• Paint Brush
• Short Nap Roller Cover
• Fine Grit Sand Paper (4 or 5 sheets)
• Joint Compound or Spackle
• 3-5" Spreader
• Cheese Cloth or Tack Cloth
• Screen Goo Kit or other Projection Screen Paint
• Flat Black Paint
• Wall Primer
• Wall Paint (for finishing the rest of the wall)
• Liquid Nails
• Finishing Nails
• Painter's Tape

How to Build a Home Theater Screen:

• Seal and Smooth the Wall
• Apply Primer Coat
• Tape Off Dimensions of Screen
• Apply Screen Paint
• Add Border Mouldings
• Paint Remainder of Wall

Seal and smooth the wall. One of the key factors in a successful screen is that it is smooth and flat. Surface imperfections will be glaringly obvious when you turn on the projector. Take your time with this critical step.

Check the surface for bumps and holes. Fill and sand any imperfections with spackle (or joint compound) and a fine grit sandpaper. Use a wide bladed spreader and draw it across the surface several times from different angles to keep your repairs even and smooth.

If your wall has been damaged, replace it (or at least the portion that will become your screen) with fresh construction. It will take less time than trying to smooth out major imperfections and provide better results.

To help identify problems, shine a bright light, like a painting lamp, across the wall surface (the light should be close to the wall.) The harsh light will create shadows that reveal the surface imperfections on the wall.

Apply primer coat. Once you have repaired the surface of the wall, you need to apply 2 coats of white wall primer before applying the screen materials. This is also another chance to smooth out minor imperfections.

Apply the primer with a spray gun or with a short nap roller. Take care not to overwork the primer on the first coat. Joint compound and spackle are water based. The wet primer will soften the material, and if you continue rolling over the same area, the patching material will begin peeling off onto your roller. Make this first coat quick and even, and then let it dry completely - check the label for drying times.

When the first coat of primer is dry lightly sand it with a fine grit sandpaper. This will help remove any minor brush and roller marks left in the paint. (If you use a sprayer, still sand between coats.) Wipe down the entire surface with a tack cloth or cheese cloth to remove the dust.

Repeat this process for a second coat of primer.

Tape off dimensions of the screen. Before applying the screen surface, tape off the dimensions of the screen with blue painter's tape. Take care measuring both the height and width of the screen and also centering it on the wall. You will want it centered left-to-right and slightly above center top-to-bottom. If you already have your projector installed, project an image onto the wall and use it as a guide.

Apply screen paint. Apply the screen paint onto the wall according to the manufacturers instructions. Most preparations involve a base coat material and a top coat. I recommend spray application for this step, but good results are possible with a roller as well.

Remove the tape and let the screen dry completely before moving on.

Add border mouldings. To finish the screen you need to add some kind of border. It could be as simple as a painted edge, or as involved as a fabric covered frame and curtains. You can really go nuts at this stage. For simplicity, I will assume you wish to create a simple frame made of mouldings you can buy at the local home center.

Start by painting the moulding with 2 coats of flat black paint. It is much easier to paint the moulding before you install it. Then you only have to apply touch-up paint once it is on the wall. The flat black finish will absorb any light around the edges of the picture and provide a nice clean look. All manufactured screens and movie theater screens have a black edge for this same reason.

Using a miter saw (or miter box) cut the moulding to length using 45 degree angles at the corners. Apply black paint to the cut edge before you nail up the moulding. I also recommend using a little glue on each piece as well as finishing nails. Use a nail-set to countersink the nails.

When the frame is finished, fill in the nail holes and any gaps in the mitered corners. Apply touch-up paint to even it all out.

Paint the remainder of the wall. Now you can finish painting the rest of the wall. Paint around the screen like it was a window. Having a dark wall color around the screen will improve the overall viewing experience, but you may have to sacrifice perfection to blend into a multi-use space.

Your screen is done. Pop the popcorn and pour the sodas!

Helpful Resources and Websites:

DIY Home Theater Projection Screen - Detailed Plans Included! www.DIYTheatre.com Screen surface paint kits
www.goosystems.com Screen surface paint kits
www.backyardtheater.com Forum for people building outdoor home theaters
www.avsforum.com Discussion forum for hardcore home theater fans
Do-It-Yourself Projection Screen Tutorial for making a stretched-fabric movie screen

About The Author

Andrew Seltz is a Go-To Guy! His wide range of interests and experiences have made him a walking search engine for his friends and colleagues. His passion for film and video production have made him particularly interested in Big Screen Televisions and Home Theaters. Visit his site:http://www.AndrewSeltz.com.