Free Projection Screen Frame Instructions

The frame shown here is a 16:9 aspect ratio and about 106" diagonal. You can also make a 4:3 aspect ratio or any custom size you like.

What size screen material do you need?
Check out the b-aDeals screen size calculator! Click here.

Materials Required:

Keep in mind that the sizes shown in the diagram above are outside measurements, so adjust for the lumber size you use. I suggest using 1"x4" white pine boards that you can purchase from your local Home Depot or home improvement store. You can also use 1"x4" fir stripping boards if you like. They are priced at under $2.00 a piece, but they do tend to dry and split.

The best way to start making your frame is to cut your outside 1"x4" wood pieces and lay them out on the floor touching one another as if the frame were put together. Make sure you have the correct size (height and width) that you want. Now measure diagonally across opposite corners of your frame. Measure 2 times in an X pattern from corner to diagonal corner. Do this from the top right corner to the bottom left corner and note the measurement. Then measure again from the top left corner to the bottom right corner and note the measurement. You will get 2 measurements. If the 2 measurements are the same, your frame is square. If they are not the same, move one side of your frame up or down and measure again. Do this until both measurements are the same. Now your frame is square and ready for the corner plywood bracing pieces.

Cut 2 pieces of 1/4" plywood 12"x12" square. Now use a straight edge and mark diagonally across from one corner to the other corner on one of the 12"x12" pieces. Cut on that mark and you have 2 corner pieces made. Do the same with the other 12"x12" piece to make the other 2 corner braces.

Make sure your frame is still square. Lay the 1/4" plywood pieces that you just cut on the 4 corners of your frame. Position one of the pieces so it matches the corner. Now put a mark on the frame pieces at the end of the plywood so you will know where to put glue. Remove the plywood piece and put glue on the 1"x4" frame pieces up to your marks. Lay the plywood corner piece on the frame over the glue and nail or screw it in place. Do the same thing for 2 of the other corners. Before you do the last corner, check and make sure your frame is still square by measuring diagonally across the corners of the frame in the x pattern again. If it is off a little, you can adjust it now before you fasten the last corner piece on.

Now you can cut a piece of 1"x4" for the center of the frame. Lay it in place and make some plywood braces for it. Fasten it in place with the glue and screws or nails. Let the glue dry overnight and you now have a light but very strong frame ready for screen material.

Lay the screen material on the floor with the back side (felt or rubber side) facing up. Lay your frame on the material with the plywood pieces facing up. Center your frame on the material. Start at the top of the frame and fold the material over onto the back of the frame. Fasten the material to the top piece of the frame at about the center point of that frame piece first then pull it snug and fasten it at the ends of that piece. A staple gun works well for this but don't over do it just yet. Wait until you get all 4 sides tacked.

Now go to the opposite side of the frame and pull the material snug and fold it over onto the frame. Start to fasten the material in the middle and work your way out to the ends of the frame. Now do the other 2 sides the same way making sure to pull the material snug as you go. Turn the frame over and make sure the material is snug and wrinkle free. Adjust if needed and finish fastening the material onto the frame. When you get to the corners of the frame, fold the material over and fasten it in place.

If you want to add a black border to your screen you can paint and fasten any trim pieces you want on the front or sides of the screen frame.

www.b-aDeals.com has provided these projection screen frame instructions for free. If you have any questions or need help with these instructions, please e-mail us at QUESTIONS@B-ADEALS.COM.