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Projection Screen
What you’ll need:
Get together for a movie night, build a custom
Projection Screen.
Dremel SM20 Saw-Max™
4000 High Performance
Rotary Tool
Other Supplies
• 6 - 8' Planks of Furring Strip
• 1 - 8' plank of 2" x 4"
• Large Sheet of Fabric
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•
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Drill Driver
Staple Gun
Wood Screws
Movie
Dremel SM500 3"
Wood & Plastic
Carbide Wheel
SM600 3" Wood
& Plastic Flush Cut
Carbide Wheel
150 1/8" Drill Bit
SM840 Saw-Max™
Miter Guide
SM842 Saw-Max™
2 x 4 Cutting Guide
*You can find projectors online or at your local electronics store
Step-by-step instructions
Determine the desired size of your finished screen
first. Here, we used standard 8' lengths of furring
strips for the long sides: the top and bottom of the
frame and cut two pieces of 6' furring strip for the
sides using a Saw-Max fitted with a SM500 Wood and
Plastic Blade.
Secure all pieces of your frame together by joining the
sides using thin wood screws. Use your Dremel Rotary
Tool and a 150 1/8" Drill Bit to drill pilot holes before
screwing together so as not to splinter the wood.
Tip: When drilling pilot holes using your Dremel Rotary tool, set your tool
to a higher speed for harder materials and at a lower speed for softer
materials. For this project we are using pine furring strip which is a softer
material. Set your Variable Speed Dremel Rotary Tool to 15,000 RPMs
for this project. If you are not sure which speed setting to use to achieve
15,000 RPMs, refer to your tool user manual or check the
'Product Support' tab for your specific tool at Dremel.com.
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Projection Screen
Secure supports in your frame by placing 2 foot lengths
of miter cut pieces of furring strip in all four corners. To
do this, you will need your Saw-Max tool, a SM600 flush
cutting blade and a miter guide. Place the miter guide
flush against the furring strip. Clamp the guide in place.
Rest the Saw-Max against the guide as you begin cutting
and move the tool smoothly through the furring strip.
Cut the opposite end of the furring strip at an opposite
45 degree angle so the piece can fit flush against the
inside of the frame. Miter cut 6 pieces of 4' lengths in
total and save the two extra lengths for step 6.
Tip: The miter guide can make cuts at varying degrees. Here we are
making 45 degree miter cuts.
Secure all four pieces of miter cut supports using the
method in step 2.
Stretch a length of cloth 8 1/2' wide and 6 1/2' tall
across your frame. Secure the stretched cloth using a
staple gun.
Tip: Secure the cloth slowly around all sides of the frame and ensure that
tension is even across the screen. Pulling too hard before securing staples
can create ripples in the finished screen. The best type of cloth to use for
a movie screen is something heavy that is made to keep light out, such as
curtain backing which can be found at fabric stores. To give your screen
more of a reflective property, many specialty shops and online retailers
carry projection paint products you can apply to this cloth.
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Projection Screen
BACK VIEW
SCRE
EN
Additional
Support
2x4 Leg
To create a stand for your screen, cut a 2" x 4" by 8' plank of wood in half. Make a
mark in the center of your plank of wood, 4' down. Cut on this mark using a Saw-Max
and a SM600 Wood and Plastic Flush-Cutting wheel and the 2x4 cutting guide. Lay
these pieces flat underneath your screen on the left - and right - hand sides of the
screen as shown in the diagram above. Using wood screws, drill the frame to these
legs. Add additional support for the legs by attaching one of extra miter cut pieces of
furring strips you saved in step 3 from each leg on your screen stand to about 1' up
the side of the frame.
Tip: To cut a 2x4 - place the guide near your measurement marks. Leave about an 1/8 inch between the guide
and line to accommodate for the kerf of the wheel and its slight offset. Clamp the guide in place. Make your
first pass, then flip the board over to complete the cut all the way through the 2x4 on your second pass.
Don't forget to pre-drill your frame using your Dremel Rotary tool so as not to splinter the wood.
Tips: For the Best Outdoor Movie Experience:
• Start your backyard events around dusk.
• Keep power cords out of the way as much as possible.
• Know the weather forecast for your movie night before setting up.
• Keep your projector away from pools and BBQs.
• Turn off your sprinkler system before setting up.
• Consult your projector owner's manual for specifications on outdoor use.
Additional supplies to consider for your outdoor movie night:
• A power strip and extension cord
• Inexpensive upconverting DVD player (if not included on your projector)
• Entertaining movie
• External speakers (if not included on your projector)
• Food and beverages (beverages and food should be kept away from all electronics)