Building your own DIY projector screen is a fun project that can save you money compared to buying a pre-made screen. With some simple materials and tools, you can create a screen customized to your space and needs. This guide will walk you through the process of building an indoor DIY projection screen step-by-step.

Choosing a Screen Material

The screen material is the most important part of your DIY projection screen. The right material will provide a smooth, reflective surface that boosts image brightness and clarity. Here are some good options:

White Paint

White matte or eggshell paint provides a budget-friendly screen material. Be sure to apply at least 2 coats to ensure an even, opaque surface. Smooth any drips or brush strokes with fine sandpaper.

White Fabric

White polyester or canvas fabric works well for a flexible, collapsible screen. Medium weight fabrics around 200-300 GSM provide good thickness. Bleached muslin or white bed sheets also work in a pinch.

PVC Board

PVC foam board provides a rigid screen material option. Look for ultra-white boards rated for outdoor use. Seal edges with aluminum tape to prevent yellowing over time.

Projection Screen Paint

Specialty projection screen paints contain glass beads to enhance image reflection. Follow application directions carefully for best results. Useful for painting directly on a wall.

Projection Screen Sheeting

Materials like Rosco White and DuraTrans come in large rolls optimized for projection. Excellent image quality but more expensive than DIY options.

Consider the desired screen size, portability, and budget when selecting a material. Sample swatches can help choose the right surface.

Calculating the Screen Size

First, determine the ideal screen size for your space and setup:

• Measure the distance from the projector lens to the screen wall.
• Check your projector manual for the recommended throw distance range and projected image size range at that distance.
• Pick a screen size that falls within the recommended range for bright, focused projection.
• Consider the screen aspect ratio (width vs. height) based on projector specs and content. 16:9 is common for home theater.

Err on the larger side if possible, as a bigger screen improves immersion. Use an online screen size calculator to determine dimensions.

Allow extra space around the edges for frame construction and mounting hardware. Center the screen on the wall horizontally and slightly above eye level vertically.

Building the Frame

The screen frame provides structure and allows you to mount and stretch the fabric evenly. Here are two options:

Wood Frame

1. Cut 1×3 or 1×4 boards to the desired inner frame dimensions using a miter saw.
2. Assemble into a rectangle using corner brackets and wood glue. Use a carpenter’s square to ensure 90 degree angles.
3. Drill pilot holes and sink wood screws into the corners and every 12-16 inches along the joints. Predrill lumber to prevent splitting.
4. Attach L-brackets along the inside edges to provide backing for attaching screen material.

PVC Pipe Frame

1. Purchase appropriately sized PVC pipes and 4 corner elbow joints for the inner frame dimensions.
2. Dry fit the pipe segments into the elbow corners to form the rectangle frame.
3. Use PVC cement to permanently bond the pipe connections. Allow to fully cure.
4. Secure right-angle brackets along the inside to provide attachment points for screen material.

The benefit of PVC pipe is that it’s lightweight but rigid. Size the pipes for sufficient stability.

Attaching the Screen Material

Stretching the screen material smoothly across the frame completes the projection surface.

Fabric Screens

1. Lay the frame on the material and cut to size with several extra inches on each side.
2. Working on one side at a time, pull the fabric taut across the frame and staple every 2-3 inches along the edge.
3. Rotate the frame and repeat on all sides, periodically smoothing wrinkles. Overlap corners.
4. Trim excess material once fully secured. Consider reinforcing edges with tape.

Rigid Screens

1. Cut panel to match the exact inner dimensions of the frame.
2. Using the L-brackets as a guide, drill pilot holes and attach with small screws.
3. If needed, apply aluminum tape around the edges to mask white framing.

Avoid over-tightening screws/staples to prevent distortion. The screen should be flat and smooth without bumps, reflections or hotspots for optimal image quality.

Mounting the Screen

Heavy duty mounting is critical for a permanently installed screen. Consider the wall material and weight when selecting hardware.

Wall Anchors

For drywall, use hollow wall anchors and screws spaced every 16 inches along the top and bottom of the frame. Pre-drill holes slightly smaller than the anchors.

D-Rings

Screw D-rings into the upper corners and sides of the frame. Use metal picture wire anchored to the wall studs to hang the screen. This helps keep the screen taut.

Brackets

Secure metal brackets to wall studs and attach to the screen frame for robust fixed mounting. Ideal for larger screens.

Stand

For a movable screen, build a wooden base with an upright support board. Attach the frame to the support board with L-brackets.

Use a stud finder to locate studs for secure attachment. Make sure hanging hardware is rated for the screen’s full weight.

Finishing Touches

Add these final touches to complete your DIY projection screen:

• Paint frame black – Use flat black paint/spraypaint to minimize frame visibility and reflections.
• Light blocking – Light leakage around the edges can wash out projected images. Install velvet trim or foam tape around the perimeter to absorb stray light.
• Ceiling support – Add a narrow shelf above the screen to hide ambient light sources. Paint it black to avoid light spill.
• Projector mount – Install a ceiling mount bracket aligned with the screen center for optimal projection.
• AV components – Place Blu-ray players, streaming devices, receivers and speakers in an equipment rack for a clean, integrated home theater setup.

With good planning, quality materials and precision craftsmanship, you can create an immersive viewing experience with a DIY projection screen tailored to your space.

Frequently Asked Questions

Here are some common questions about building DIY projection screens:

What size projector screen should I build?

Consider the size of your room, seating distance, and projector specifications when deciding on screen dimensions. As a general rule, allow for a viewing angle of 30-40 degrees for comfortable viewing without excessive head movement.

Does the projector screen frame need to be wood?

Wood provides a sturdy option but PVC pipe or aluminum framing also work well. The key is constructing a frame that keeps the screen material taut and flat.

What is the best white paint for a projector screen?

Flat or eggshell paints with a light reflective value (LRV) between 70-85% work best. Behr Silver Screen and Benjamin Moore Silvercoat are often recommended. Apply multiple coats for opaque coverage.

Can you use a regular white wall as a projector screen?

It’s possible but not ideal. Wall imperfections like texture and uneven paint can degrade the projected image. Dedicated screen coatings and materials enhance brightness, clarity and contrast versus a plain white wall.

How do you make a projector screen stand?

One method is using 2x4s or similar lumber to construct a rectangular base frame with an upright support board anchored at the back. Attach your screen frame to the support board with L-brackets. Then add trim pieces for aesthetics.

What fabric is best for DIY projector screens?

Matte white or grey polyester/canvas blend fabrics around 180-300 GSM are suitable for flexible screens. Bleached muslin, white bedsheets or ripstop nylon also work in a pinch. Avoid fabrics that are too thin or have sheen.

Should you paint the frame around a projector screen?

Yes, painting the frame black helps make it visually disappear into the background when watching movies. This prevents light reflections and draws full attention to the projected image.

How do you tension a projector screen DIY?

Use staples or screws along the frame edges to tightly stretch and secure the screen material. D-rings and picture wire can also help maintain tension for ceiling mounted screens.

Final Tips

• Mask border edges with black tape or velvet to absorb excess light and enhance contrast.
• Position the screen so ambient light doesn’t fall directly on it. Draw blinds and use dimmable lighting.
• Place speakers either behind an acoustically transparent screen or to the sides at ear level.
• Room acoustics impact sound quality. Add sound dampening panels and thick rugs over bare floors.
• Match the screen aspect ratio and resolution to the projector output for efficient use of the projected image area.
• Allow at least 1.5x the screen width between the projector and screen for best image size and focus.
• Clean the screen surface periodically with microfiber cloths and approved screen cleaners to remove dust and improve picture quality.

With robust construction techniques and the right screen material, you can build a top-notch DIY projection screen to transform any room into an immersive home theater. Carefully plan the design, finely craft each component, and enjoy the rewards of big screen viewing for less.

Conclusion

Creating your own projection screen is an extremely gratifying DIY project. Follow the steps in this guide to build a screen customized for your space and projector setup. With quality materials, precision measurements and sturdy construction, you can achieve excellent image quality for an affordable price. Position it ideally, fine tune the installation, invite friends over and immerse yourself in the big screen viewing experience. Once you learn how, you may even find yourself helping others build their own DIY projection screens inside too!