Thread: Help needed to construct a projector enclosure

So let me get this straight you are wanting to build a case for a projector you are building from parts?
If so why? :confused:

Then consider this. You will have a high temperature lamp and optics enclosed in a timber case. This is ringing alarm bells big time.
Thentheres the electronic shielding and electrical compliance matters to consider.

chjeers

Didn't Barry White build one of those projectors last year?

Is this one of those large tv screen projectors?


Peter.

Have a look here mate. The results from this projector have amazing results: http://www.lumenlab.com/forums/index.php?showtopic=5141
They last longer, and are much cheaper to make or replace compared to other bought high end projectors in the market. They cost very well above $1k and the bulbs used are rather expensive. The projector I intend to build uses 400W metal halide bulbs which have ratings of 20,000-30,000 hours MTBF and cost less than bought ones

Have a look at the website and see what results those folks are getting. Point to note though that pictures don't do justice to the real thing. It's quite a tricky thing to capture images in the dark especially a projected one as they always seem washed out, grainy and low quality due to compression.

The design of the enclosure also factors in fan placing and cooling to cool the internal hardware. Toughened glass will also be use and heat shields to protect the other equipment from getting over heated. My only biggest hurdle is building the wood enclosure.

Cheers!

Yes, this is a large screen projector Sturdy

And by no means this is one of those gimmick items you see at eBay going for $9.99 which require to turn your TV upside down . While this one i'm trying to build can be a little costly as a DIY home project, the results justify the costs.

Sweeeeeeeeeeeet!

Thanks for the intro to the forum De Cruelz... Another project for me...

No prob at all Woodlice! Look out for the Aussie forums there. There's quite a bunch of us but some of them aren't really active anymore though

I did a search on this forum and found Barry White's projector thread as mentioned by Sturdee. Here's the link: http://www.woodworkforums.ubeaut.com...ad.php?t=11303

Now, if I can find someone to help me create a custom job. Here are some pictures of how I'd like to build mine.

Side view



Lens and LCD mount

Its an interesting concept.
rip a perfectly good lcd moniitor apart & build it into a box as big as a dinosour three tube projector.
I can certainly relate to the replacement lamp cost thing.
I supose its an interesting project. But I don't believe for a minute that it would compete with a current 1500 or 2500 lumen native xga machine.
but hey what ever flaots you boat.

My comments regarding the timber case still stand. I work with theatrical lighting equipment and I know what intense heat and even light on its own can do to materials in the long term. I would be building out of metal.
cheers

I think the major benefits are the cooling, the price of the lamp and filter and the coolness factor of having both an aesthetic box and the fact you can design / build it yerself.

If you are interested in quality - go for a system like the SXGA Panasonic has for sale at $125000 US.

Hi soundman, from what i've seen people compare with, entry or mid level projectors only do upto 800X600 resolutions and aren't as sharp as the one discussed here. Those projectors cost quite a bit over the $1000 mark. Quality is also not as good according to those that have built it and done some side by side comparisons. I'm merely quoting from what i've read though so don't hold me to it

Also, the very first prototypes several years back and revised, complete units built today have been built with wood and presented no problems whatsoever even in the long run. Ofcourse heat management is important and thats why fans, ducts, exhausts and such have been added to the design to control internal temps. Also i'm guessing building out of metal will be a whole lot more expensive and also would require the right tools.

Also, I have to agree with Woodlice about the coolness factor having built something yourself and having total control of the aesthetics of the final product.

Anyway, i'm still looking for people in Sydney who can help me build it. I have the plans in 2D but don't have the tools or skills necessary for this project. If no one can help I guess i'll just stick to the simple box design, have it cut by Bunnings and put it together myself.

Originally Posted by soundman

Its an interesting concept.
rip a perfectly good lcd moniitor apart & build it into a box as big as a dinosour three tube projector.
I can certainly relate to the replacement lamp cost thing.
I supose its an interesting project. But I don't believe for a minute that it would compete with a current 1500 or 2500 lumen native xga machine.
but hey what ever flaots you boat.

My comments regarding the timber case still stand. I work with theatrical lighting equipment and I know what intense heat and even light on its own can do to materials in the long term. I would be building out of metal.
cheers

Soundman

Believe it or not it works and mine has been running for nine months and the temprature even during the summer inside the box never rose above 36 deg C and there is hundreds of these operating all over the world.

Like you say whatever floats your boat. Just because you haven't done it in your expert opinion, doesn't mean it wont work.

It's like they said man would never walk on the moon and look what happened.

It just comes down to design.

The technology used in this type of projector should give a much better image than a typical commercial projector that costs $3,000 plus mainly because the LCD that is used as the source of the image is 14 inch but in a commercial projector the LCD is only 3inch maximum (if that).

The real difference is compactness and that translates to cost. A small commercial projector has the globe adjacent to the lens and LCD and if you used the same form of light source as in the larger home made version the whole thing would just melt. So in order to get compact you have to go with much higher precision equipment and globes that give off lower amounts of heat in comparison to the amount of light and that means money.

But to be honest de_cruelz, I think you may be disappointed if you get somebody else to do it. It isn't just the woodworking that is required, it is the adjustment for accuracy. I would worry that unless the person making it for you understood what they were doing in terms of the optics etc, you'd end up with a great looking box that didn't work very well as a projector. Is that right Barry?

Originally Posted by simon c

The technology used in this type of projector should give a much better image than a typical commercial projector that costs $3,000 plus mainly because the LCD that is used as the source of the image is 14 inch but in a commercial projector the LCD is only 3inch maximum (if that).

The real difference is compactness and that translates to cost. A small commercial projector has the globe adjacent to the lens and LCD and if you used the same form of light source as in the larger home made version the whole thing would just melt. So in order to get compact you have to go with much higher precision equipment and globes that give off lower amounts of heat in comparison to the amount of light and that means money.

But to be honest de_cruelz, I think you may be disappointed if you get somebody else to do it. It isn't just the woodworking that is required, it is the adjustment for accuracy. I would worry that unless the person making it for you understood what they were doing in terms of the optics etc, you'd end up with a great looking box that didn't work very well as a projector. Is that right Barry?

Simon

Pretty well everything you say is true except that probably the woodwork involved can be important or not depending on how good you want the projector to look. There have been some very ordinary projector boxes built that have produced some awesome picture results and the people that built didn't really care about the appearance of the projector but just wanted to watch the big picture.

When you buy the guide from Lumenlab they provide you with all the critical dimensions to build the projector. Provided you maintain those critical measurments, how rough the box is doesn't matter.

I put a bit of effort into my box because it was going to sit in my lounge room and I am pretty happy with the result.

Here is a link to the Lumenlab Projector Gallery with some good boxes and some not so good but all have produced excellent outputs.

http://www.lumenlab.com/forums/index.php?showforum=3

Hi Simon, that is pretty much precisely what i've read regarding commercial projectures, the LCD and size/heat/performance related to it making it more expensive.

Regarding the build of the box, I only need someone to build it according to very detailed 2D drawings that I have acquired from the website. Alignment for the optics can be done simply by adjusting the frames for the lenses as that too has been designed to be adjustable

Barry, your box is one of those nicer ones and outputs great images too. I was wondering what did you use to finish it with that black look? By the looks of it I think I will make my own box by purchasing the wood from Bunnings and perhaps a jig saw to get the job done. I think it would be a lot cheaper than having someone to build it for me and also I get to refine my wood work skills

I'm seriously considering making one. I've just got one question and what is the noise of fans like?