This weekend I built a super-cheap, no-frills, 108″ projector screen for my family room home theater. A modest setup consisting of a Pioneer 7.1 AVR, some DIY speakers and sub I built years ago and a 50″ Panasonic plasma HDTV. We’ve got the usual array of sources as well – a Panasonic Blu-ray player, Xbox 360 and the ubiquitous Home Theater PC (long live Windows Media Center!). I’ve been toying around with the idea of a garage theater for the last year, so I do have a projector, but have yet to bite the bullet on formalizing some kind of air conditioning out there, so in the summer months, movies in the garage come at a fairly high cost of nearly sweating to death.
I always thought it would be fun to just bring the projector in the house and project on a wall so we could watch movies in the (air conditioned) house, but there was just no good place to put it where there was easy access to the existing home theater equipment and a good wall to hang a screen. That’s when I started concocting a plan, a plan which involved making a super cheap screen which I could actually hang from my existing entertainment center in front of the TV/stereo/center thus making the transition from TV time to full-blown-movie-going extravaganza as easy as hanging a picture on a wall. And since I wasn’t sure how this would work out overall, I started out thinking this would just be a proof of concept only, so I did it as cheaply as possible. This whole thing only cost $28. So far it’s worked out so well, I see no reason to upgrade or change it out for something “better”. So without further adieu, I offer up this tutorial and a few pictures for you so you too can transform your family room home theater into a bigger, better movie experience for less than it costs to take the kids to Chick-fil-A.
List of materials:
Qty (3) yards Roc-Lon Blackout Fabric (white/white or white/beige) from Joann’s (54″ wide) – $12 (with a 50% off coupon) normally $7.99/yard – don’t forget the coupon!
Qty (4) 3x1x96 inch furring strip pine lumber – $6 – The Home Depot
Qty (6) 2×4 inch Simpson Strong-Tie Mending Plate – $4 – The Home Depot
Qty (2) D-Ring Frame Hangers – $2 – Walmart
Qty (2) Small Caribiner – $2 – Walmart
Pack of 3/8″ Heavy Duty Staples – $2 – Walmart
List of Tools/Supplies:
Titebond II Wood Glue
Orbital Sander and 60 grit sandpaper
Cordless Drill and Drill Bits
First and foremost, let’s talk about the Roc-Lon Black Out fabric. They sell 4 different colors as well as mixed front/back colors but you want to note the color of the backside of the fabric because that is the side you will project onto. The frontside, the side that is rolled outwards, has a bit of a texture to it, but the backside is smoother, has almost no texture and is more rubbery – that is the side you care about. My Joann’s had a white/white, a beige/white a beige/beige and an ivory/white (front/back) to choose from. I ended up getting the beige/white because the roll had more fabric on it and looked like it was in better shape. I was worried about whether or not wrinkles would iron out or not stretch out properly. You just want to make sure that the backside is white, but the frontside doesn’t matter as much.
Turns out that you can iron this fabric and small wrinkles will stretch out so you don’t have to be too fussy about the condition. Quick tip though, bring your own 2″ cardboard role and after they cut it have them re-roll it onto your own role, otherwise they will fold it 3-4 times over which creates creases. They did this with my fabric and I didn’t think any of it at the time, but it creased badly, which meant I had to spend 30 minutes trying to iron out all the wrinkles, which like I said you can do, it does work, but it’s extra time that would otherwise be unnecessary if I had just been a little more prepared going to the store. They may have extra rolls there too you could ask them nicely if they’d roll it for you. Also, don’t try and iron the rubbery side, aka the projector side or backside, it doesn’t work well and will ruin the texture on that side, you have to iron the frontside/fabric/texture side. It’s still not easy to iron a huge 54″ x 108″ piece of fabric though, without creating creases as you iron out creases just trying to manage this beast of a piece of fabric on a tiny ironing board.
So I had purchased the Carl’s Place Sampler Pack a couple of months ago and was planning on buying one of their premium screen materials, so I was able to compare some of their samples to Joanns’ Roc-Lon blackout cloth and here’s what I can say about the similarities. The “frontside” of the Roc-Lon blackout is very close to “backside” of the very popular Carl’s place standard white Blackout Cloth. It’s got the same type of fabric-like texture to it, it’s almost the exact same color white and has similar stretching properties although the Carl’s Place Blackout cloth is slightly more flexible/stretchier. But the backside of the Ron-Lon fabric looks and feels almost exactly the same as the frontside of the Carl’s Place Blackout cloth, which is why if you buy this fabric, you will want to project on what is effectively the backside with respect to how it’s rolled, since it matches the definition defined by Carl’s Place as “the smooth texture side with a rubber coating faces the audience”. Both materials are the same thickness as well measuring 0.014 inches [0.35mm] thick. Visually, using projected content, the Roc-Lon and Carl’s Place blackout cloths are nearly indistinguishable in terms of white/black levels and color balance. I observed no obvious hot spots or changes in texture or sheen that would be observable or distracting in any way.
I’ve got some pictures of the fronts and backs of both fabrics in both natural light and projected light so you can see the differences. I’d probably have to give the edge to the Carl’s Place Blackout if I were being super picky about the texture, because the fabric texture bleadthru from the other side is ever so slightly less obvious on the CP Blackout cloth than with the Roc-Lon Blackout but we’re talking nanoinches. And it depends on which location in the fabric you’re looking at. Click on the two pictures above and you can see what I’m referring to. This is with natural light, it is far less obvious with projected light. Of course the most obvious disadvantage to the Joann’s stuff is you’re limited to a 54″ height. Which works out to about 53 usable inches vertically (once you wrap and staple it to a wooden frame) and 94.25″ horizontally which makes for a 108″ total diagonal screen with a 16:9 aspect ratio. Carl’s Place doubles that to 110″ allowing for some extremely large screens.