Materials for build:
Sherwin Williams paint- Gray Screen in flat, 1 gallon
1 1/2 inch wood trim - flat
Metal L brackets - 4
Small bottle of Gorilla Glue
Double stick tape
Painters tape
1/4" nap paint rollers (2) tray, stir sticks and handle
Joint compound
2 cans flat black spray paint
Total cost: Around $60

I measured screen size from blue screen off projector. 120 inch diagonal at 16:9 format. Bought trim at Lowes and had them cut to size. Make sure you help them get the cuts STRAIGHT. Layout frame on flat surface (I used garage) Tape down frame after checking 90 degree angles on all 4 corners. Use gorilla glue and metal L brackets. (It WILL hold) Key: apply double stick tape now, leave outer paper on.

Frame taped to garage floor with L brackets and double stick tape applied.

Carefully flip frame over (2 people) Inspect corners. I had gaps at joints.

Use joint compound to fill gaps.

Sand joints when compound has dried.

2 coats of flat black spray paint. 3 hours between coats.

Masked off screen size with blue screen from projector. I added 1/2 inch all around so paint edge would be covered by black frame. Used wet-line paint technique. Two coats with 4 hours between coats. I used a fresh roller for each coat. 1/4 inch nap roller will give you a very smooth finish. Be patient with it- the paint lines will not disappear until paint is dry.

Finished product. My house is only 1 1/2 years old and I bought it new so wall was actually perfectly smooth. I did not have to do any prep! I had help bringing in frame. After removing outer tape from double stick, we lined it up and stuck it to wall. (You only get ONE chance) I then did some fine tuning of projector image.

I Robot screen shot. Screen is in 16:9 format. Diagonal for 16:9 is 120" viewable, and diagonal for 2.40:1 is 110" My room is 14' wide and 15' long with 9' ceilings. Projector throw distance is 14'

I did not really notice a huge difference when room is blacked out, but the picture does look much better when there is ambient light. I chose the Gray Screen paint for this reason.

Gallery rating:

(4.9) (26 ratings) Show ratings

Gallery rating:

(4.9) (26 ratings) Hide ratings

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Comments (19)

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Comments (19)

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jonmoz  » May 02, 2010 02:54 AM

Nice clean setup and awsome homemade screen.

jjmbxkb  » Mar 25, 2010 01:45 PM

Admire your skills, and appreciate the tips on painting the screen.

Turnda643  » Nov 08, 2009 02:32 AM

Awesome DIY instructions. And your HT is top notch. Props to you my friend!!

BluePotato  » Aug 18, 2009 06:59 PM

Beautiful work! A+. I'm doing the same, except stretching blackout cloth over the frame and wrapping the frame in black velvet. And mine is only 98". If I were a single man, it would be 120", but I'd still choose my wife over 20" of additional screen dimensions.

burngwngs  » Aug 18, 2009 08:04 AM

Nice job man. Looks great and I bet you saved a crapload.

ht_skinny  » Jun 25, 2009 09:45 PM

WOW! That is totally amazing! I might have to give this a try when I get my basement... and a house!

Grevlin  » Jun 11, 2009 06:42 PM

Thanks Vega, I actually considered the 2.35:1 format. I watched movies for a few days to get used to the size, and then when my HD cable popped up- it just filled the wall a bit more. The viewable on widescreen is around 110" so its BIG. This screen will probably last me 6 months before I upgrade to maybe a manufactured screen. Apparently bulbs slowly dim over time, so I will go for a higher gain >1.0 Considering the short expected lifespan for this screen, I went economical and got it up for $60

vega2K  » Jun 11, 2009 05:48 PM

Very very nice! So easy to do with a huge bang for the buck. I may have to consider this if I ever get my basement back from my kids. I would make two modifications: (1) CIH 2.35:1 screen (why not? Hell you could even add removable masking panels for 1.85:1 movies ) and (2) I would cover the frame with velvet material to make it look even more professional.

got rice  » Jun 08, 2009 11:25 PM

I wouldn't expect anything less from you. I've never seen this technique before, very simple yet functional. Awesome.

Grevlin  » Jun 07, 2009 11:07 AM

Thanks DLS_222, your HT is one of my favorites. My room is VERY bare right now, I need to give it some color and acoustic treatments to give it that "slick" look, like yours...

Grevlin  » Jun 07, 2009 09:45 AM

vickie, -Its a paint color called Gray Screen from Sherwin Williams. It is a regular interior wall paint in flat. I got the color off some other forums, and while some add stuff to the paint or give it an additional top coat of something, I just used two coats straight from the can. I do believe I have a negative gain (less them 1.0) because of the gray color. I had some people over last night and they couldn't accept that it was paint on the wall and a wood frame- they were staring at it from like 3 inches away for a while before saying "ok, its the wall."

-DLS-  » Jun 07, 2009 01:54 AM

Nice job man looks real good!!!

vickie  » Jun 06, 2009 06:27 PM

Quick question: Is it a special kind of paint for projected images or just normal interior wall paint?

PitbullMike  » Jun 06, 2009 03:23 PM

Awesome job,It came out super nice and If I didn't know you made it I would have thought you paid alot for it

Grevlin  » Jun 06, 2009 02:38 PM

Thanks, I have the Panasonic AE3000 projector. I did not include pics of everything because I'm finishing the room with other acoustic treatments and various other little tweaks.

dolphinc  » Jun 06, 2009 02:26 PM

That looks GREAT, you have inspired me to do the same thing. I have a 20 x 15 room with no windows I have been thinking about setting up something just like what you have done. Can I ask what projector you are using?

SupaSweet  » Jun 06, 2009 02:17 PM

Interesting, i am the same way, i have no patience, when i envision something I must have it right away!!! Well, from the screen cap it certainly looks great, and on the flip side you constructed the frame already so if you ever decide to go with screen material you can measure and staple away!

Grevlin  » Jun 06, 2009 12:40 PM

Well, I couldn't really decide on a material or manufactured screen but wanted something NOW - you know... I decided to just throw this up. It cost $60 in materials, and really does look good. I watched The Fountain last night (for the first time in HD) and it was simply amazing. The black levels are really improved with the gray paint when there is ambient light- useful during day for normal viewing.

SupaSweet  » Jun 06, 2009 12:34 PM

very cool man, looks like a fun project! Can i ask why you did not go with material vs paint/wall?

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