I have been on the site here for almost two years, in this time I have made a few projectors. my first one is still going strong and will be two years old in August.

I have made Two fully working Haas style projectors for other people, one is in ohio, the other is at a friends house who I owed a favor and He said build me one of those and we are even. this is the thread of these two builds and the test projectors for the ones I build now.

First the parts.

one Haas style enclosure
focus ring from menards (2" shower drain)
LL standard lens set
LL e-ballast
mogul base
ED28 bulb
120mm 120vac fan
DPDT switch
fuse holder and fuse (important)
terminal strips
sheet metal for shielding
Lexan XL-10
IKEA napkin ring reflector
stripped samsung LCD and driver circuts
16 gauge wire ( wht, blk, green)
attic fan thermostat
digital temp sensor
quick release clips
foam for seal

first the Enclosure

next we need a way to mount the bulb and make it adjustable for distance to the rear fresnel careful measure and marking makes sure of proper alignment in the finished product.

bulb mount and adjuster in keyhole slots with 3/4" standoff

mogul mounted to base and held in by keyhole screws

next we do a little painting

the reflector, mount, and lower shield

E-ballast installed

wiring done 16 gauge wire, twisted to prevent inducted noise, this is important for the wires from the ballast to the bulb.

back panel wiring, fan, fan thermostat, DPDT switch, terminal strip, fuse holder and fuse.

closer look

back of enclosure ready for back panel

back panel connected to enclosure

back panel installed

different veiw of the back panel before the reflector and mount are in

test fitting the lens, it is held in with a few wraps of black electricians tape. this should than be press fitted into the focus ring. this should be a snug fit, not loose not too tight. the three acorn nuts are there for easy turning of the focus ring and do not hold the lens into the housing.

rear fresnel frame test fit

laser test for alignment

rear fresnel frame, Lexan XL-10, sides of sled.

different view, the frame mounts to the side rails and is 1/2" off the bottom for air flow

view from the bulb side, top rail of the fresnel frame is removable for install or removal of the fresnel lens.

top and bottom rails for the LCD supports installed in the side rails, keystone blocks and keystone rod installed, frame loose for wiring of lcd, ED28 bulb installed, reflector adjusted to bulb.

looking thru the lens opening

wiring for the LCD controller board pulled under the lower support bar for the panel, the bar has foam weatherstripping under it to prevent air and light leaks. also the power supply is installed in the front out of the FOV and connected to the a/c for the ballast so the lamp switch will also provide power for the panel.

different view, shows the foam better

rear fresnel installed

main board installed, VGA,RCA,S-Video,coax to T V tuner. this has a remote so the IR eye is mounted in the bottom of the panel and there will be no need for a hole for the manual controls, this will keep the case looking clean and uncut.

test hang front fresnel,adjust for alignment.

How far is the distance between front cover and front fresnel, also between front cover and lcd?

the distance between the front fresnel and the lens is 300mm/330mm there is a half inch gap between the lens side of the panel and the first notch on the keystone block the rod can be moved

stripped panel ready to be installed

panel installed in enclosure

front fresnel reinstalled

overhead shot, upper heat shield installed

different view

finished projector with the lid on, on it's stand, and fired up.

PJ1 in the background, wickermans pj in the front

screen shot in my home on my wall

one more screen shot in my house

now over to wickermans basement where this will reside. he is in the process of finishing the basement and this is a temp set up. the image is on a primered wall 103" diag at about the same distance from the screen. this is the angle we watched it at with no keystone issues

the screen

fifth element

taking the dive

Taxi

building lelu

more

this PJ has been running for a while now with no problems, fires up in under five minutes with the LL e-ballast. good picture, after many hours of run time it stays nice and cool (82.6 degrees F ) with (1) 120mm 120vac fan. when we are done watching both switches are shut off and the fan stays running until cool down in about 20 minutes.

here are some pics of a different build, this one has a BIG eye bulb. the case is wider to house this bulb but it can be done.

This build uses the 8" ikea blanda blank, M-59 core and coil ballast, sheet metal flashing, two 120mm fans.

parts placement