Black Widow Ultra 16:9 thin bezel screen build

Soldato
Joined
25 Jan 2006
Posts
3,071
Location
Gateshead, Newcastle
Hi guy's,

It's been a while since i've been active on the forums since i've moved home and the missus was insistent I wasn't allowed a projector in this house. I've worn her down by giving an ultimatum of either spending ££££ on a bigger LCD 65"+ or getting a projector which worked out at less than half the costs.

I bought a relatively cheap Optoma HD141x which would give me an 87" image at the throw distance I have. I didn't want to go any bigger as I'm projecting onto a chimney breast wall and didn't want to have to have an electric roll down screen which would hang over the edges of the wall.

I'd been wanting to do a thin bezel and seen so thought I'd bite the bullet and make a start.

I've ordered all the stuff for the screen, I went for Grey Steel 2 as i found 1 would be way too dark for a living room environment.

Yesterday I started to install the projector. I wanted this to be as neat as possible, I decided to run a flex spur from the downstairs ring main, Luckily I had the house re-wired and know where all the cables are, Pulled up a full length of floor board and added a junction box and ran my cable off of that.

I also ran 2x CAT6 for my HDMI and IR to my media cupboard, If you want more info on that you can see my house build log in the sig.

Power and Networking being ran.

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Skip a lot of time ahead and I'd installed this into the ceiling downstairs and wired up.

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Projector In place

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45cm drop from ceiling to projector giving me a 55cm drop from the ceiling to my image on the projected wall.

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*Temp image onto a sheet as I'm still waiting on the paint and tape arriving to make the screen.

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*The wall behind the sheet had a cut out for my old tv, some of the image in the middle appears darker because of this.
I'd sold my TV so this had to be done to get some tv viewing in.

I've got 3mm di-bond panel to be sprayed onto when the paint arrives, This will be attached to a wooden frame with ultra strong tesa double sided tape. I plan on spraying the screen with GS2 and AAA. I'm going to have a 10mm border with deep black tape.

All of that should be done in the next few days assuming all the items arrive in the post.
 
I started the frame and managed to get the dibond stuck on and hung in place.

Squaring up the frame and levelling up
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Stuck the dibond to the frame using tesa double sided tape. I was a bit dubious as to the strength of the tape
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Test image, got to be painted and get the edge tape on.
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I should hopefully have time to get the screen painted tomorrow and let it cure before applying the edge tape.
 
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Is there a guide or something that explains the paint material to use etc?

There is extensive thread's on AVForums and AVS forums about paint mixes. The only issue with those on AVS as its an american website is that they use paints that aren't available in the UK readily.

There are a few around that you can use but i've went for the Dulux Grey Steel 2 and Auto-Air Aluminum Base Fine to give it a neutral tone and add a bit of reflective-ness to improve white's.
 
So i'm in the middle of painting and thought i'd upload some pics while each coat dries out.

Make shift paint booth in place.
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Paint Mixing
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You can just see the tiny aluminium sparkle in the paint here.
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First mist coat. thin multiple layers is the way to go im told.
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More pics to follow as things progress.
 
Finished Article

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Black and white contrast image
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Dark screen in the light (10x 6w LED's in this room)
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All lights out on the same image
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Video of a colour demo playing whilst i turn lights on and off. I have LED's hence the flicker at the end of the clip.
 
After the screen had cured over night I added an 8mm border using Deepblack tape, I used 2" tape cut in half and wrapped it round the sides and back. to make the sides look a bit neater than bare dibond sheet.

Not the brightest day but I have 10 x 6W LED's on and both sets of blinds open, French doors at the bottom end and a 2.2m window at the other end.
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Very nice :)

I'm really tempted by a projector for my new flat as my living room is long but fairly narrow (5m+ by 3m+) and due to the layout viewing a TV will be across the length of the room.

Problem is how to get power to the ceiling when it's a flat and has 3m+ ceilings :/. HDMI is fine as I can use wireless. Any ideas lol?
 
Very nice! If I ever have the space this is what I'd hope to achieve! Not bad contrast considering the background light levels either. I bet it's awesome at night! This has also made me realise that it's compulsory to run lots of Cat6 around our extension!
 
There is extensive thread's on AVForums and AVS forums about paint mixes. The only issue with those on AVS as its an american website is that they use paints that aren't available in the UK readily.

There are a few around that you can use but i've went for the Dulux Grey Steel 2 and Auto-Air Aluminum Base Fine to give it a neutral tone and add a bit of reflective-ness to improve white's.

Interesting, when i did this this my base paint was salmon shade from a mix station and the gray came from the Aluminum Base after mixing.
 
Very nice :)

I'm really tempted by a projector for my new flat as my living room is long but fairly narrow (5m+ by 3m+) and due to the layout viewing a TV will be across the length of the room.

Problem is how to get power to the ceiling when it's a flat and has 3m+ ceilings :/. HDMI is fine as I can use wireless. Any ideas lol?

It's not the best solution but running the power up the wall is going to be the easiest solution. try using some D-Line trunking.

Really smart :)

How easy was it to set up the IR receiver presumably your media server is not in the same room?

Im using Octava HDCAT-IR which runs HDMI and IR over 2x CAT cables.

Very nice! If I ever have the space this is what I'd hope to achieve! Not bad contrast considering the background light levels either. I bet it's awesome at night! This has also made me realise that it's compulsory to run lots of Cat6 around our extension!

CAT6 everywhere would be my recommendation. I didn't run any at the point of the build because I didn't think i'd be going this route but it's definitely working putting it everywhere.

How is it only after recently setting my projector up I'm now jealous of someone else's!

Damn you OP! :p

Sorry about this. I had no plans on doing this till I seen it done on another forum

Interesting, when i did this this my base paint was salmon shade from a mix station and the gray came from the Aluminum Base after mixing.

The Aluminium base makeup has been changed and now doesn't tint the paint so you need to use a neutral grey paint to start and the aluminium just adds the reflective property needed to get the brightness.
 
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