I've been perusing Lumen Labs forums and store for quite some time now and now have finally taken the leap into the world of DIY Projectors! The reason for this project, besides having an awesome projector, is to get some more design experience under my belt. I'm a recent grad and want to get into product design. Luckly I work at a place where I get to build stuff and have access to machining equipment and CNC's (and "scraps" of material).

Well so for the past two weeks I've coming up with designs with a buddy of mine and have been collecting the parts needed.

Parts List:

LL Mega Kit: $334.00
CMV CT-520D LCD: $150.00 @ MWave.com
Antec 3 Speed Double BB Fan: $20.00 @ Frys Electronics
12" x 24" Lexan XL10: $9.00 @ Home Depot

---------------
Total (so far): $513.00



Whats kind of a bummer what that, after I purchased all these parts, the EVO projector comes out... and then Black Friday comes and my buddy purchases a Optoma DLP Projector and 100" pull down screen for $399!!!

Oh wells... the purpose of building is still there and I'm sure my projector is going to be better (I hope). The good news is that since my buddy doesn't have room for the screen at his apartment, it is now mounted in my house. So eventually when I finish my projector, there will be some comparisons.

I've already stripped the LCD, wasn't even in my house for more than a couple of hours and already disassembled. I was only on for a little while to check for dead pixel and to see if it worked. Kinda feel bad about it... Oh well

There is a tutorial on how to strip this monitor in the Pro Guild. Thats one of the reasons I got this specific monitor, the other reason is cause it has a DVI input.

I am contemplating on taking of the AG. Everyone seems to love it after its been removed and I've been reading that its easier when its new, but it is an extreme mod and don't know if I'm willing to take the risk yet...

This is the triplet holder I've made.





I am going to make a ring that this holder will sliding in to give it some adjustment. I read that 2" of adjustment is recommended, so the ring will be 1" deep and this holder is 2" long. This gives 2" of adjustment with at least 1/2" of engagement. I might go a little larger to get more adjustment. The holder is made of aluminum and the ring will be either aluminum or some gray PVC. Another benefit of this holder and ring is that it allows me you use a 4" hole saw to mount the assembly and not have to deal with Metric units. Its not that I don't like the metric system, I love it in fact, it just sucks finding metric tools here in the US.

I'm going to design the parts to be some want modular so I can change the design of my box with little effect on the three main parts: triplet assembly, LCD and fresnel assembly, and the light gate. I thinking that the box will be somewhat like samuraijack's artdeco, with some elements of pun15her's P-Cubed.

Finished the triplet mounting ring



even machined down a set screw and made a little delrin pad so it won't mar the lens holder:



Here it is assembled:



and the back side...:





I knurlded the back so it would provide a tighter fit into the hole I drill and hold it in better. I't also provide a better surface to glue onto if I need to. I wish I could have knurled all the way up to the shoulder but the tool I was using didn't allow me to do that and I was impatient to wait for the machine that had a tool holder larger enough for the one that could have done it...



I was wondering what would happen if you didn't cool the bulb at all? Like if you made a housing for it with vents so the hot air could escape, but no fan to help move it.

Input and constructive criticism is welcome.

If all the pieces and parts on your PJ get this kind of attention to detail, you will have a very nice rig; without a doubt. Keep up the great work!

Zeroluck,

Nice work! I will second what Minous stated above. I believe that Pun15her is making a PJ called Psquared that will be fan free. Good luck with getting this done (its a lofty goal).

Lovely job so far

Can you tell us more about the sort of enclosure you're going to end up with, or is it all very hush ?

Thanks all for the kind words!

Enclosure..... hmmmm.... the truth is that I haven't really decided... HAHA It all kinda just floating around in my head right now. The one I'm thinking about right now is going to be kinda like SJ's Art Deco PJ. Basically I'm going to have three main parts tied together with a curved beam on both sides. The light box is probably going to be similar to Pun15her's and its going to be exposed.

I'm not exactly sure of what it'll look like in the end yet. Thats why I've been designing the parts to be modular and pretty much work in any style of enclosure.

Right now I'm still working on the light box. Having a little trouble because the bulb is so freaking huge and cooling it will be and issuse. Also since it might be exposed, I want it to look cool too.

I need some help.

I was wondering if there is a significant difference between mounting the bulb horizontal vs. vertical?

I was reading some where that vertical was better, but I also saw some results showing more improvements with a horizontal orientation.

The reason I'm asking is cause I can't seem to design a vertical light box that also looks good, but I don't want to sacrifice quality for a little looks.

While reading Slashdot today, I saw this article about a "DIY Mid Air Point Device"

check out the article: http://www.linuxdevices.com/news/NS9902727147.html

and the Home Page: http://www.patrickbaudisch.com/projects/soap/index.html





I looks pretty nice and seems easy to use and best of all, ONLY COST $35 to make yourself!

would be great for HTPC users. You can mouse quickly with out a surface and looks pretty easy to use. This definitely will be in the works for me

Great job on the triplet, looks great.

The mouse is a great concept. I think I might try it out. Looks like it would work great with media center.