So, everyone seems to favor a really heavy MDF or Hard Wood solution to build their projector boxes.

Would it be completely out of the question to design a projector that has an aluminum frame, and 1/8" lexan on the outside?

I ask because I make a horrible carpenter, but I know how to get aluminum CNCed and lexan laser cut.

Or maybe, the same aluminum frame, but 1/16 lexan, covered by 1/16 acrylic? (pretty designs then!)

I've seen a diypj made from lexan, can't find the link now though.
The problem with acrylic is the danger of it melting, but decent cooling and thick lexan with heat resistant spray paint should do the trick. I'm no expert though.

A lot of ppl choose MDF beacuse its cheap and easy to use... Its heavy yes, but its also very stable etc..

here is a link for Joe2000Chevy build using Black plexi glass


http://www.lumenlab.com/forums/index.php?showtopic=4114


here is a build on another forum made from aluminum

http://www.diyaudio.com/forums/showthread.php?threadid=80944

That thing is unreal!

Oh man, that aluminum one is ... wow.

I do recall seeing the black one before, its nice and compact. Thanks for the reminder!

I always liked this plexi design, which appears to be a matter of scoring, snapping, and sanding, but that is what I gleaned from Google. I think I would use acrylic or plexi next time because MDF has been too dusty over time. I keep having to clean it out.