Well, the day has finally come.

Much like the greats on this site, I did a lot of research, played around with my first Retrofit OHP projector mod (although I felt it wasn't lumenlab worthy), but I think I've learned enough about DIY Projectors to tackle a personal favorite of mine, Garfing Sharks' Sharp 15.4'' WUXGA Storage Bench build. For my BOM, I'm going off of Garfing Sharks' list (logically), but I will be making some slight alterations to my design to fix some awkward things I noticed about his build plus try to work on some of my own demons I'm making for myself on this build. (More on that later)

Currently, this is what I have in my possession thus far (Updated 5/19/08):

From Jonjandran:
- 15.4'' WUXGA Screen (Samsung model)
- MST Controller v1.3 (HDMI, VGA, Component, S-Video, RF plug, 720p native)

From EBay:
- VU-LYTE III 18'' Triplet Lens (Gutted from an 1945 Opaque Projector - yeah, it was OLD my friends but a RARE find indeed. *coughs from dust*)

From Wal-Mart.com:
- Walnet Finish Storage Bench

From Office Depot:
- Elite Screens 100'' Tripod Screen (For Game Room to replace my 64'' "box" screen I used with my Dragon Projector.)

From 3Dlens.com:
- 3D Lens Fresnel Lens 550mm
- 3D Lens Fresnel Lens 220mm

From RadioShack:
Screw-Cap Panel-Mount Fuse Holder

From Lumenlab.com:
LL Vue 400w eBallast
LL 65K T15 Lamp
LL Mogul Base HID Socket

From Mouser.com:
2 8 Position Dual Row Barrier Strips
3 120mm 120VAC Exhaust Fans
3 120mm Fan Grills
2 80mm Fan Grills
AC Receptable
Double Pole Single Throw Switch

From Home Depot/ACE:
Lexan Polycarbonate
Manual Thermostat
Light Shield (aka 12'' Mud Pan)
10A Slow-blow Fuse
20ft 24Gauge Wire x3
High Temperature "BBQ 1000 Degrees F" Spray Paint
...and lots of wire crimps, nuts, screws, etc

One thing missing...
LL Pro Projector

Grand Total of Build including Pro Projector thus far: $1037.29

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I'm working on acquiring the rest of my parts by mid month, including the LL/Vue 400W eBallast, Fresnel Lens, the LL 65k T15 Lamp and HID Socket, plus the other little trinkets I need to get this build a-rollin'.

I'll be taking alot of pictures once I begin my build so stay tuned for that. In the mean time, I'll be working on getting my Game Room/Garage ready for this behemoth. It might not be the greatest of setups, but it'll definitely work for me.

Alright guys, I promised pics so here ya go!



This is a picture of the lens gutting process. It's hard to tell in this picture (because I sized it down) but if you look on the left, the sticker reads VU-LYTE III (so you know it's good )



This is a close-up shot of the 18'' Beseler Lens completely gutted from the Opaque Projector. Sorry the picture is kinda blurry. I will probably get a new camera before this build is complete.



This is the first of my demons that I'll have to contend with if I wanna keep it in my build, the focusing mechanism from the Opaque projector. Basically what happens is the lens will sit on two rails and then the knob will move the lens forward and back. Considering the shape of the actual "object" I might use the same design but not use that actual piece.



Here's another shot of it from the side.



...and for anyone that's curious about the retrofit, here it is. *Again, sorry for the sucky quality* It's made from a Dukan 653 portable projector (although it's not portable now if you don't count the stand it's on lol) and the monitor is a Gateway...something or other 15''.

I mainly use it for movies since I don't need the whole screen to project it and Media Player Classic is a great app to size up your movie to whatever size you need it to be for your monitor for those of you who are having some edge problems on your OHP projector like mine. Mine was unavoidable but just for movies, it's great *and the occasional 360 game when I can sit there and tweak it to fit in that "sweet spot" where nothing obscures the picture.

That's why I'm building this projector, to game and view movies in true HD. (Yeah, it's not full HD but who can tell at 720p ^^)

Looking good so far!

Any thoughts on the focusing mechanism, Garfing? I didn't really see if you salvaged yours or not, but I'm just wondering if there's a way to actually save at least the concept of that focusing mechanism (the gears, the rails and the knob) and just make a new housing for it.

Well, I finally got my orders from Lumenlab this morning (thank you Customer Support!) and Mouser.com so I'll be able to do a good bulk of the projector build before the Pro Reflector comes back in stock on June 9th. If any of you have a Pro Reflector to sell, please pm me or drop me a line at the Trading Post "post" here.

It's off to Home Depot on Saturday and then I'll put some major muscle to this project.

Well, I just came back from the "Depot" and I managed to grab all but one part, the Thermostat. Apparently, they were fresh out of that kind of thermostat so we then ventured over to the White Jones ACE hardware store and I found a manual thermostat.

It's similar to the Thermostat that Garfing Sharks used but it only goes to 90 degrees. Still, this is very good since I don't want the components to get that hot.

I also scored a laser level so I can make some straight lines in this puppy and start aligning my optics and all of that good stuff. Still, trying to learn Garfing's method of aligning his optics with the rails is going to take some work.

I also am working on designing a custom plate that'll go on the outside of the projector vs. Garfing's "hole" that you'll see on the left hand side of his projector box. I'm designing it using Datapro's Plate Designer.

I think with this setup, it'll add a good bit of "professionalism" to this build.

Once I settle in here, I'll factor in a final cost for everything I bought thus far and I'll compare it to Garfing's build. I may have went a little over his cost of the build, but it'll be pretty close.


...The mountain calls to me. It says "Build...me."

Couldn't you use that as a template and buy a blank plate from the Depot and drill the holes yourself. It seems an awful lot to dish out for a faceplate. You could probably get somebody local with a metal cutting CNC to do that for cheaper then Datapro is charging.

According to Datapro, for a 4 gang Aluminum plate, they're charging 30 bucks, and the cutouts will be 22 bucks. ...plus, I'm not sure who does any CNC cutting around here. The rest of the price is going towards the couplers and I'm working on the list of the runs right now for the HDMI plate mounts and all of that. ...without shipping costs, it's up to $220.45. Maybe someone can help me find a better solution but still get the same or similar result?

Example of the "finished" custom plate:

Here ya go Gang! More pictures! (Again, I apologize for the crappy quality of the pics)

There she is! Garfing Shark's projector is coming back to life!



Here is a view of my Triplet lens from the front. As you can tell, I'm working on the keystoning issue that Garfing Shark has with his build. The reason why I "beveled out" the triplet lens section is once I get all of my optics and electronics in the case, I can adjust this on the fly up or down until I nail the picture, then this front section will be remade to make it more clean.

Eventually I would like to get to this, NinHowFritz's idea from the original build:





Here is a very WIP picture of the focusing mechanism posted in my 2nd post but I modified it quite a bit. The first thing I did was took off the main casing so it would just the bottom rail system piece and of course the Beseler lens. Next, I reversed the direction of the mounting system so I could mount it inside of the case. When I did this, the focusing knob was on the wrong side of the case so I transposed the knob from the left hand side to the right hand side. As you can see, the knob will be inside the case at all times. That way, I won't have to mess with the focusing system that much once everything is dialed in but, the knob works so well that the lens won't fall out the case *I would really have to force it forward*.



...and here is some work I did on mounting the E-Ballast and cut the holes for the Exhaust fans. I gotta make another trip to the Depot so I can get the right size screws to mount the fans.

All and all, first good full day working on the projector.

Today, I added another bracket to the triplet lens assembly so it had more support, installed the rails into the enclosure and once I got all of that set, I painted the inside of the case with my BBQ Spray Paint (High Temperature Black paint).

The next thing I'm going to start on will be the electronics. (Getting the fans installed, wiring those up to the terminal strips, installing the thermostat and cutting out some holes for the AC Receptacle, Fuse Holder and Toggle Switch.) I'll take pictures of the case again (this time with more light) once I get started on that part.

NinHowFritz, if you're reading this thread, could you explain to me more about your lens shifting idea? Am I supposed to cut the field fresnel lens to size to get the physical fresnel center aligned to the triplet lens center? It looks like the rest of the set up is fairly normal compared to other designs I've seen. I won't be attacking that part until I know for sure what I have to do to make it work. Any help/suggestions would be appreciated. Thanks!

I'm back guys, this time with High Quality Pics!!! I'm still working on getting a new camera for my build and for my August trip, but this the best thing I can get my hands-on on such short notice. The originals of these pictures were much much bigger.



Here, you can see how I slotted the Triplet Lens support so I can move the lens up and down. My step father is working on getting me an aluminum plate to update the look on the front once I get the Vu-Lyte lens lined up with the Field Fresnel lens.



...and Here is a picture of the back of the storage bench with the holes cut out for the Exhaust Fans. I received the Wiring Schematic from Garking Sharks' projector build so I'll be ready to work on the Electronics next week.



Here is another look at the Triplet Support from inside of the projector. This time, we're looking at the focus mechanism. The reason why it's inside is because once I get the picture set, I'm not touching that knob.



Finally, here is a new picture of the Triplet lens cover, now in Krylon's Metallic Finish Spray Paint color. This is going to compliment the new side panel I'm getting from Datapro tomorrow and it'll match the fan grilles as well.

....I know alot of you are saying, I can see! I can see! ...Don't worry, I hope to have my new camera some time in June.

Here is a picture of the Side Panel with all of the couplers and extensions attached. You know the drill about the quality of my pics...

I started working on the Electronic wiring last week and I hit a snag wiring the projector, so I'm going to take a break from the projector build a bit so I don't fry what's left on my brain, figure out just what the heck happened and wait patiently for my Pro Reflector to come in (which be next week!!).

Anyone have any thoughts on the lens shift issue?

Final cost for the build for those who are interested: $1257.74

Dude, some serious cabinet envy. Gotta find me something like that storage bench to put mine all in. I grow less and less fond of the idea of having this thing just sitting there.

Also that jack plate is hot. I just did up one of mine for my setup, and it would add $117 to my build. But so cool. I think I'll just do it the lazy way, and mount my board right up next to the edge of my box.

I'm abandoning this project to get some of that green back in my pocket: http://www.lumenlab.com/forums/index.php?showtopic=27330