I have been lurking the forums for a number of months now, popping up here and there to ask and answer questions. I am finally to a spot where I can begin working on my projector. A couple of months ago I got a DEL 17” LCD 1704 fp that I stripped and broke somehow. I have since then replaced it with a DELL 17” 1707fp, which I am much happier with.

I wanted to make sure the LCD would make a good candidate, so I proceeded to strip it. I have a write up on the process and will post it here.

Below I will list my design ideas and the parts I plan on using:

Design:
I plan on making as compact a box I can. So far I am looking at making something like the Baker’s Box, but I will add my own touch to it. The projector will be a ceiling mount, and will either be in a room with a 9.5ft throw, or a 14 ft throw. This all depends on if my wife allows me to use the extra room as the theater room.

Well much has changed in the month or so since I first posted this. I learned family sucks, higher paying jobs are good, and I might actually finish this before the end of the year. The wife and I have decided against the ceiling mount projector, and have agreed upon a vertical fold design, ala punisher style. I have been given till December to finish, so I need to get cracking.

I am in debate whether to include a HTPC into the projector design, but as of now there is going to be one. The projector will feature a 17" LCD powered by a 150w ceramic arc bulb. A pre con is a definite, but will be added on after the build. The same goes for the AG, if all goes well this will be coming off too.

The HTPC has been put on hold, and the wife has requested I get an up converting DVD player with either the DVI or HDMI. I am looking into a few of these, but not sure what I will get. I guess it will depend on how my Christmas bonus looks.

The wife and I have also decided to make the projector for the main living room. If all goes well, I have a second 17" I will make for the garage (for sporting events, no smoking in the house ), but for now I will focus on the first projector.

Parts:
17” DELL 1707FP (Purchased)
150w Ballast (maybe an eBallast, sourcing right now)
Philips CDM 150/TD/942 150w ceramic Arc Bulb (more than likely will get from bulbworks.com)
HQI Socket (Home Depot (Purchased - $9.99))
2 x 330mm Fresnels (eBay (Purchased - $50 Shipped))
330mm Triplet (Lumenlab.com (Purchased - $29.99))
Pro Reflector (lumenlab.com (Purchased - $14.99))
FS mirror (?)
Walmart Special 6 12x12 mirrors (Walmart (Purchased-$9.99))
Pre-con? (Surplusshead.com) (I have some pre cons from an old projector I might try and use)
Blackout cloth (will order when I see how big I want to screen to be)

Misc
Threaded rod (Home Depot (Purchased - $4))
MDF for the enclosure and framing (Home Depot (Purchased - $16))
1/4 nuts & washers (Home Depot (Purchased - $6))
Misc tools (Home Depot (Purchased - $38))
Paint, hinges, nails, wood filler (Lowes (Purchased - $23))


Total ~ $181.98

Dell 17" 1707FP Strip

I have listed most the details on the images, but I will try to fill in the other details.

Fist off I removed the stand.

Next I pried the edge to remove the front and side bevels.

Step 2b

Step 3: Removed the back patrs.

Step 4a: Remove the stand holder and the USB cover

Step 4b: Detailed removal of stand holder

Step 4c: Removal of the USB cover

Step 5: Removal of back cover

Step 5b: Removal of back cover

Step 6a: Unplug circuit boards from each other

Step 6b: Remove the power circuit

Step 6c: Remove the video controller

Step 6d: Remove the USB controller

Step 6e: Remove all circuit boards

Step 7: Remove screws for video board cover

Step 8: Remove casing for LCD. Remove backlight optics.

Step 9: Bare LCD ready for install

At this point the screen is ready to be used as you see fit. I tested the screen when finished and luckily it still worked. Here are a few shots of the screen working, the refection of the bare screen, and the barcode from the sceen.

It is difficult to see the screen because I was testing a new light source. I should be upgrading my light engine next month, but for now this is what I used.

That not Charles angels is it?

You need to look at the fresnel and triplet.

The 330mm fresnel goes with the 330mm triplet
The 550mm goes with the 18" triplet
The 600mm (pro fresnel) goes with the pro lens.


You should look at the throw calculator here.

http://www.lumenlab.com/forums/index.php?s...ost&p=90009

The 17" LCD with a standard 330mm triplet will put the PJ in front of you or right on top of you.

It’s actually an image of Sin City. My wife chose it as here background, but not for long since here computer will be donated for the HTPC.

I have been looking and thinking of the lens I want to go with. I have been searching eBay for an 18", but was not sure if it will be much better than the standard triplet, other than throw distance. Of course the Pro lens will be my best bet, but then I will need a behemoth box hanging from the ceiling. Since most things I will be projecting will be 16:9, I was going to try the standard triplet first. If this does not work, I was going to go with the 18", and as a last resort I was going to use the pro. I have a buddy who I can sell the parts I don't use to. If I end up putting this think in the living area, I will have 14 ft of throw, in which case I will most likely need the Pro lens. I am hoping I can use the extra bedroom, which will be dedicated as a theatre room.

We will see as the project progresses.

Well you have a 17" LCD already so if you want a small box go with the standard triplet with a fold. It has better focus. One of the smaller lamps might fit better too like the ceramic.

Try to make the box thin so from the celing it won't block your view.

You could use 1/4 hardboard for the top and bottom and even use a few deg of tilt for the LCD and lamp. You might be able to make the box only 12" tall or even slighly less.

Yeah, I do have a nice LCD, so I would hate to skimp on the other parts. I have been following the ceramic lights, and its seems plausible, but there is the cost involved. Another thing is the 400w MH is tested and true. I might just build up a cheap version to learn from, then once I see how everything is going to work upgrade. I have been eyeing the 15.4 WUXGA displays. They make my mouth water.

One of the most important things I have to deal with is the wife factor. She is very open minded, but has said she does not want a monstosity haginng from the ceiling. My other otion was to make a folded, ala punisher, design and just roll it out for movie watching.

I will be more clear on my direction next month when I begin ordering parts, and as soon as the wife and I come to terms on where we will be placing the projector.

Here are the room layouts I need to shoose between.

I was thinking about using two Dell CPU fans, like in the pic below, for the rear of the projector. The design of the fan looks like it will keep the light leaks down, and they are rated at about 30cfm. Has anyone tried these or think they would work for cooling the light engine area? I plan on having seperate fans for the LCD and frenals.

30 cfm.. pretty wussy. Also, that style fan is often very loud.

Well after discussing things with the wife, my plans have changed. I will be going with the folded design that will be on the floor. I am thinking about a Punisher style with casters. This way the projector can be rolled out to watch a movie, and stored away when not. She is determined to have the projector in the living area, and to not have anything hanging from the ceiling.

I will be reviewing more of the 17" folded designs, but a modified punisher style gets major points with the wife. I have been given the green light to start production in T minus 15 days.

Luckybob,

It is now T + 14 days. Have you started your PJ? Please provide an update with pics please.

When you get the green light from the wife, you need to act quickly!

Cheers!

Fulcrum

If you're already considering PJ II with a WUXGA, you may want to build PJ I, play with it till you've learned what you need to learn, and then go for one of the new 7.1" 1080p LCDs. No date as to when they'll be generally available, but it's on the horizon for sure. And what the heck...you'll have a bitchin' 17" PJ to watch movies on till they are out.

Just a thought. Best of luck on the build.

Ok, things were put on hold due to family issues and me getting a new job. Without going into to many details, my dad is a deadbeat and needed a place to crash, but little did I know he had ulterior motives. Needless to say this has been fixed. Also I had a job offer I could not refuse, so as of October 16th I no longer worked for Company A, and now work for Company B(yeah). Onto what is important.

I just got word from the wife that the projector has to be done by December, or else. I have ordered the triplet and the pro reflector from lumenlab. I am now trying to put together the other parts.

Since I will be using a 17" LD, I needed to find fresnels somewhere else. Well 3dlens.com was the first choice, but they are not local to the US and the shipping might take awhile. Luckily I was pointed to a guy in Florida, thanks GLAPPE, who sells for just about the same cost, but I can expect to get them quicker. I am waiting for a response from him regarding the grove pitch on the fresnels he sells.

I am trying to get an eBallast from ballastwise, but am waiting for them to confirm their 150w eBallast will work with the bulb I am purchasing. If I don;t get a reponse by Friday I will be getting the magnetic ballast from Prolighting.

I am waiting on ordering the bulb, cause I want to find a cheaper place for the mounts. I will be ordering the Phillips CDM 150/TD/942 from bulbworks.com for $32, but they charge $15 per mount. If I can find it cheaper I will just order the bulb.

Aside from that I have priced what I need from home depot and will be making a trip to get the materials as soon as the fresnels come in.

So now that things have calmed down on the home front, and the parts are in the process of being ordered, I can continue on with my PLOG.

Does anyone know where I can get an Rx7s base for cheap?

Well i began work on the projector today. Boy I thought I would have got more done than I did. I got the frame up with 4 threaded rods, and cut the frames for the fresnels and lcd. I only got a chance to almost finish the LCD frame. I should have got started earlier than 2pm and should not have let myself get discouraged by a trip to wal mart, thanks hun.

Anyway I will try to get more done tomorrow and post some pics. I still don't have a light engine or my fresnels, so I won't have a pic to display for a few weeks, but I am shooting to have it assembled by them middle of December.

Luckybob,

Just in case you get your light engine before your fresnels, you can still get an image on the screen without the fresnels, although the fresnels will help picture brightness and light evenness. How do I know? I was conducting an experiment to determine which way my LCD screen had to be positioned so that the image was right side up. I pulled out my old original PJ box, and found that just using the triplet, I could get a nicely focused image on the wall (See my post#230ish in my plog). Please realize that after you place the fresnel into the PJ, that the triplet will have to move slightly to focus, maybe 3 to 5 mm. Oh, and the image on the screen will get bigger as well, with a fresnel.

The bottom fresnel helps to distribute the light, while the top fresnel helps to throw most of it into the triplet.

Of course without the fresnels, your air flow path to cool the LCD will be non-existant, but if your itching to show the wife a demonstration, a few minutes without any air flow won't hurt.

Cheers!

Fulcrum

Yeah I have an old panasonic projector I took apart and found many interesting optical parts to setup a test rig. It was designed for like a 1.5in LCD, but I re-aligned the optics to work with a LL setup, and I was able to project an image on the wall about 4'X6' of the word "TEST" (I used a energy saver 60w fluorescent light, the image was not too bad.) . The wife thought it was cool and tells me she wants this done before Christmas.

I have not been to good with updating my log here, I did start construction on the rig, but have since decided to scrap what I have and begin again. I have some nice to scale renders on my idea( a la punisher style), and am working on the enclosure design. I will be making my second attempt at the enclosure this weekend, hopefully. I should get all the frames done, with the fresnels if they ship before Friday.

I found a good deal on two(2) 330mm FL 16" x 13.5" fresnel with a .2 grove pitch for $50 shipped. The lenses are guaranteed against scratches or damage or my money back. We will see if eBay pays off.

I have a few more parts to source out, but am looking for the best deals I can get, while keeping my ever looming deadline in mind. I have a bunch of images to update, and hopefully I will get to them either this afternoon or tonight.

Ok here are some shots of what I am planning. It is very simple threaded rod design. I will try to work on the enclosure tonight.

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I have pictures of the current state, but no on me right now. I will post them tonight. It will be torn down and rebuilt this weekend.

You may want to look into turning your bulb by 90 degrees, so that the arc chamber is parallel to the vertical of the monitor. Apparently you get a more evenly lit image that way. Check out Simul8r's plog, he has done a lot more research on this than me.

Good luck!

The bulb placement was just for a visual, I plan to full tweak and optimize everything I can. I do recall reading about the bulb placement for best light coverage.

So I got my hands on a table saw...finally. I have redesigned my frames for the last time, I think. I hope to have some pics up tomorrow of what I can get done tonight.

Below are the plans for the fresnel and lcd frames.

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I was able to get a little work done. I would have had more if the wife had not invited her sister over for dinner. Anyway, here are a few pics of the frames for the fresnels and the incomplete frame of the LCD.

I still need to paint the fresnel frames black and drill the holes for the threaded rod.

I need to finish securing the LCD frame, paint it black and drill the holes.

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Another update!

I finished my cuts for the frames and the base. everything seems to fit together nicely. I needed to make a trip to Home Depot tongiht, but did not feel up to it. Here are a few pics of the progress.

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I might not e able to work on it again till this weekend, but I should get a lot done. I still have to order my bulb and ballast, so I might try to get that rolling this weekend too.

Very Nice, Very Nice!

I'm at about the same spot on my pj as you are on yours.

Keep Going, you might get it done before Christmas.

Cheers!

Fulcrum

I was able to run to Lowes after work yesterday and picked up a few more things. I have the mirror mount done, along with all the frames. I patched them up with a little wood filler last night, so all the edges are smooth and the gaps are sealed. Later this evening I plan to sand them down and give them some paint.

I still don't have a light source yet, but I might have found a good light box. At work the AC was just replaced and there was some leftover goodies. There is an insulated box with flashing and fiber glass. I was thinking of modifying this to act as my light box. I think I will take it home over the weekend and see what I can come up with.

I still have much to do along with the full assembly, I still need to:

• sand and paint frames and mirror mount
• mount my reflector
• get a light source and figure out how to mount it
• make an adjustable triplet mount
• figure out how I am going to mount my control boards and cables
• WIRING
• make a screen

I am going to try to knock out most of these tasks this weekend, but we will see.

Sorry no pics for today, but I was a bit tired after a late night of work.

It's coming along well!

Is the wife now wanting it done by Christmas, or the first of the year?

I'm hoping to have mine done by the end of January. Slow going at the moment...

Cheers!
Jon

Well she said she would like it by Christmas, but she is hounding me to finish it. We have a few movies to watch, but she refuses to watch them till the projector is built. (Superman Returns and Pirates of the Caribbean). So if I want to watch these movies, I need to get moving. I am going to order my ballast today and possibly the light. As soon as I get those parts in I will be all but finished.

This weekend looks promising to get most everything done, but I have some Christmas shopping to do tomorrow, plus the wife would like to get a tree. Rest assured I will make time to get at least something done.

Well, it sounds like you have good incentive!

I was originally shooting for the end of December, but did not take into account funding shortages and length of time for things to ship to this little town where I live. Middle of no where.

Well I was able to get some work done today between getting a Christmas tree, doing some Christmas shopping and taking the wife out to dinner. I have all the frames painted and the fresnels mounted. I did a test fit of the LCD and everything thing seems to line up well enough. I ended up making some washer from a 1 liter coke bottle and might I say they are holding up very well. I have all the frames and the mirror holder painted and in place. I did a test run with a small piece of glass with test on it. I used a 40w light bulb for the test, and held the triplet in place. Let there be a projection. I was clearly able to see test on a spare piece of MDF i had. I did not get pictures of the test as I only have two hands, but tomorrow I sould be able to get the triplet mounted.

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I got the LCD and all controls mounted but was relucant to test it for fear of the LCD not working. Well after a trip to Home Depot and some lunch I decided to hook it up....whew, it worked.

I am going to test the projection tonight when it is darker, but I am concerned about a few issues.

issue #1 The distance from the LCD to the mirror is about 6-7 inches, and the distance from the mirror to the edge of the box is about 8 inches. It seems there might be an issue with the image fitting in the triplet from only 8 inches. Now this might not be true, but from observation this seems likely. It is probably not an issue, but I would like to know the distance others have used from the mirror to the triplet and the LCD to the mirror.

issue #2 I thought I would use the sliding rail method for the triplet, but have since decided to use the drain plug method. What is the exact part everyone seems to be using? I think I will have better luck with this method.

I will get some pics tongiht when I fire it up.

Also as you can see I do not have a real mirror yet. I am using a small FS mirror from an old projector. I am waiting to see what size I might need before ordering a FS mirror.

Well I did not get any pictures last night because...well for no good reason. I did try to fire it up and see if I got something with the LCD in there, but the 40w house light did not produce a thing. I am still in search of a focusing mechanism, but I did get the info on the shower drain. I will be picking one of these up after work and giving it a shot. Today seems like a good day to order my ballast and light, so in about 30 mins I will place the call.

I was able to pick up the shower drain and I went ahead and got a 150w halogen fixture that came with the bulb connector I will need for the CDM/TD/942 bulb.

I went ahead and disassembled the light fixture and took the parts I needed. I figured I would mount the light and see what kind of results I would get. But first I would have to address the heat put off by the halogen. I have two 120mm fans from my old commercial projector, so I hooked them up. I just used a 9v wall wart, even though the fans called for 12v. These guys are quiet as hell and can move some air. The whole time testing the first fresnel never got about 80 degrees F. I was impressed since they were kind of rigged to work. I did not feel like hooking up the HTPC or my laptop, so I just displayed the Dell menu from the screen. It worked and looked pretty decent.

In regaurds to my other post about the mirror eing to small, would this make the FL of the triplet different? Right now I have to hold the triplet about 2 inches in from the edge to get focus. I first thought it was because it was only focusing on the small mirror, but now I am not to sure. I will pickup a 12X12 mirror tomorrow and see if that makes a difference.

I got the drain cut down and mounted on the first try. I am still deciding how I am going to mount it for its final resting place. Maybe after getting a larger mirror tomorrow I will have a better idea. Till then let the pitures commence.

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