Welcome to my build!!!!

After looking through the Lumenlab forums for months and months, admiring many supurb builds and seeing them fantastic results, I finally decided to bite the bullet during a month off work as an IT contractor in London and try a one of these DIY projector's that everyone's talking about.

I was at art college when I was younger and came out of university with a diploma in three dimentional design so how hard can this be!!!!!!

I can honestly say that my build has took over my life at present, and my kitchen. (I have a very patient partner) I am at the ponder stage at the moment, the design is done and now its just fitting it all in the box and getting a result, I am sure there will be many nights tweaking and changing.

I loved the look of Pun15hers build, loved the curve design and controller setting in the front of the housing. I decided to base my own build on a similar design (hope you dont mind Pun15her) but add my own personal touches.

I appretiate your feedback and any comments you can give to help me and keep me on the right tracks, so please provide input, that way we can all progress our projectors together.

Parts List

15" LCD Monitor off Ebay with a broken backlight £ 0.99
2nd LCD TV Grundig GU15WDP off ebay £31.00
FS Mirror 21cm X 26cm £25.00
400W Metal Halide Growlight off Ebay £25.00
Fresnels 220mm & 330mm from 3D lens £35.00
OHP Triplet off Ebay £ 7.99
Polycarbonate (Lexan) 8mm A4 from R.E.D. ltd £ 3.95
Mirror from B&Q £ 3.49
Soup Ladle for reflector from ebay £ 1.99
VGA Gender Changer off Ebay £ 0.99
Power switch / Fused unit off Ebay £ 2.49
MDF Various sizes and thicknesses £25.00
240V 5" Extractor Fan off Ebay £ 5.99
120mm PC Case fan £6.00
Screws / Nuts & Bolts / Threaded Bar etc etc £15.00
FFC extension & Zif connector £8.00

Grand Total £197.88

Enjoy!!!!!

Slinger


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I decided to try a focus setup using a piece of threaded bar and set the triplet in a section of pipe that fits exactly inside a slightly larger pipe. I wanted to be able to control the focus from the rear of the projector to maintain the clean front.

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It works quite well, I will show a few more pics when I can figure out the rear adjustment setup

Painted Triplet housing and mirror in place.

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Controller fitted and heat outlets set into front.

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Front picture with painted triplet surround. you get an idea of the front look with the controller panel and heat outlets in place.

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Another picture of the LCD Sled (AG removed)

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A quick look at the back of the box, with the light bulb in place, just to check out the room inside.

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Thats all for now folks!!!!!!

Maybe a lonely fresnel lens in sled then

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More soon!!!!!

Slinger

Lookin' damn good so far!

I deleted your other thread as the rules about cross-posting are pretty clear.

(There's really no need for thread "A" and another thread that just says "look at thread A"...)

Sorry Flyboy,

I keep forgetting theres more than 1 forum.

Cheers

No worries. Keep up the good work, looking forward to more pics!

wow, this is turning out pretty nice. looking forward to more, keep it up mud.

Very nice start!
I really like your inset triplet mount - very classy!

Is it just me or is the triplet facing the wrong way?

Looking good though and I'm sure that when it's done it will be awesome

It's a 15" 4:3 LCD and he's using the S15 triplet, so the triplet is inserted correctly. (Might want to include a parts list in the first post, Mudslingerdude)
LOL@"Look what I made with a hammer, some broken pallets & a few nails"
Is that 1/8" MDF on the front? If not, how did you get it to bend like that?

Could well be round the wrong way, its a triplet from an OHP that I got cheap off ebay. Until you mentioned it, thinking about it, OHP's have the shaft part of the triplet housing facing up, so, I guess that the glass is in the wrong way for this setup. I will turn the glass around in the housing sometime.

The front MDF is 1/4" and I cut it to size, screwed the botton edge to the box frame and put all my weight on the board (all 14 stone of me!!!) and screwed the board down every 9"s until it was fixed tight. It did kind of bevel a little up the centre of the curve, so I filled it with car body filler and sanded it back with a flatbed sander untill I got the shape back.

Got a bit of painting done over the weekend!!!

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Turned my OHP triplet around aswell. Had a job to get the ring on the back of the triplet housing off, cut a corner off a filling knife to fit the 2 lugs in the ring and still no joy. I was getting worried that I may damage the lens after a long time of trying to get the ring turned to release the triplet glass, so I decided to cut the ring with a stanley knife. Turns out the ring was glued into the housing. Word of warning for anybody with a OHP triplet and needs to turn the glass. If the screwed ring in the back of the housing doesn't turn in the first few attempts, cut the ring and prize it out, because if it was like mine, its glued!!!!!

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Also removed the rear reflector plastic from the LCD panel due to a scratch that I accidentally made to the back. Came off no problem after a five hour soak.

Thats it for now, time to make the lighting box and start thinking about wiring.

Tried to wire a 240 Volt 5" fan to the lighting circuit and the light failed to light. Do I need to have the light on its own supply?

Cheers all
Slinger

looks good so far

how do you plan on cooling the bulb ?

I'm in the process of making the light box now. Ive got a 5" fan that I'm going to aim between the firewall and fresnel/LCD and direct the flow down to the light box and out of the front of the projector where the 2 pipes are. Not sure if it will go to plan yet. If not then I will need to consider a second fan for the light box only. I took a picture of the light just because it was in there, lot of work to be done with the light box as yet.

See what happens.

Very nice, so far. I forgot that you're using a triplet from an OHP.
I don't know what your plans are for the exhaust tubes at the bottom, but you might want to consider lining them with something like black felt. That should absorb a lot of extra light that might get reflected. Just an idea.

Nicely done, so far. Looks really good!

why are you turning the triplet glass around?

Do you mean turning all 3 elements? please explain the purpose. Why not just turn it without dismantle?

thanks

The triplet was from on overhead projecter, so the shaft that the triplet glass is in has a housing much like the LL S15 triplet. On a OHP though, the glass (3 sections) is facing the wrong way, the very convex lens is at the front of the unit, because it faces down onto the fresnel and lamp on an OHP. So to be able to keep the front housing to the front of the projector, the 3 section glass triplet had to be turned 180 degrees.

So I did!!!! Lot of hastle, but better than just turning the triplet around and having the eye end facing the mirror and tube end facing out of the projector front.

Slinger

Quick update for you all,

Still working on the light box and the LCD Sled.
I had to take about an inch off the HID socket after I discovered that the bulb that I set the build up with was a different size to the 5200K bulb that I bought after the 1200K bulb that I based the size of the build on.

1200K

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5200K bulb before HID socket shortening.

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And after taking a angle grinder to the HID socket

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Almost back in line, maybe check this when the projector is at display state.

Did some wiring too. Managed to get the LCD panel power supply and the ballast mounted in the top of the projector, behind the mirror.

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Also got the power switch / Fuse & VGA socket set into place, ready for wiring.

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Thats it for now!!!

More photos and progress soon.

awesome paint job, i love the enclosure

Thanks mook,

Im not sure what colour top coat to go for yet, black or silver. Maybe I should start a vote count up.

oh thats primer, lol, it looks cool

I'm really enjoying the look of this enclosure so much so I'd buy one if it were available.
Awsome job

Thanks Billie,

I maybe should of thought about the possible complications a little more with this design. The main problems I am facing are that everything has to be made so it can be fitted via the back of the unit, and can be taken out if need be. Most designs I've seen of this site have been side or for the Haas type builds, top loaded builds. I think that would certainly make the build a lot easier. Not to say I am not enjoying the build, I am!!! (and look forward to the day I switch it on and see something on my wall) but some parts of the build are taken so much longer because I have to think about how to get the parts in through the back and still line up correctly. The LCD sled was a right pain, partly because I got a panel with a long controller attached to the main PCB, which means I have to hang the Fresnel between the LCD and the lamp actually on the LCD sled and still make the Fresnel so it has some adjustment.

I may get the sizes on line for other builders to have a go at sometime. still finding it difficult to get everything into it though, had to grind a corner off the ballast to be able to get it to fit behind the mirror in the top, keeps the bottom clutter free though. I had to grind the lamp socket to get the lamp lined up after my silly error with a aquarium bulb. I am hoping that the curve in the back of the projector may help with some kind of keystone adjustment mechanism. Top fresnel sits right at the base of the rear curve (if my measurements are correct)

All in all, its coming along well, and looks quite smart and I cant wait to get it up and running and tweaked to work well.

Even in primer, that looks pretty sweet.

With the amount of work that you put into the surface finish, it'd be a shame not to do that in a high-gloss paint.

Black is always classic, but you've got to keep it dusted and clean...

Silver would also look awesome, but you could probably go for something a little bolder, less neutral, depending on the room that you're putting it in.

Take a primary or secondary colour from the furnishings or carpet, and use black as an accent colour.

Im not sure what top coat to go with yet. There is a lot more work to do before the build see's any more paint. Plenty of time to think about final colour. I will keep you posted on the colour I choose.

Back at work now, so the projector build is starting to slow down a little. Still working on it every spare second I can, but long days in London are taking there toll.

Anyway!!! I had a full day on the build today and got the light box finished, along with the back draft solution for keeping the thing cool.

Check it out.

The light box reflector shield and box, box is a MDF case with a medium gauge metal box made to measure inside (heat outlet port cut and E40 socket hole cut).

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Close up of the main lamp box inside. I made this out of the shroud that the lamp and ballast came in. Glow lamp style.

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Quick test of the lamp in the box, see where everything is sitting.

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Great, all in line and looking good.

Fan fitted, drilled the holes in the reflector to blow the heat out of the front heat outlet port and tried the power switch / VGA connection board in place to check air flow to the fan and light box.


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If anyone wants to request any pictures of any of this build, just tell me what you would like me to post, and I will post them. Not sure what you guys want to see.

Cant wait to get this thing to get showing me moving pictures on a wall though!!!!

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More soon!!!

Hi there, congrats to your project. I am thinking of building one anytime soon too after I gather the materials.

My question is, how on earth do we fix up a good and focal light reflector on a MH light of this size? I have problem sourcing for a decent reflector here in Malaysia, esp those that can fit a 400W MH lamp.

Your design looks very neat, but would that cause unnecessary stray light, disturbing the 'focal' effect of the light source?


ps: I got myself a MH lamp and the necessary stuff to make the light source already, just to experiment my own ability to get this light up properly. It comes with the ignitor, capacitor & ballast which scared my butts off when I turn them on first time and hear it buzzle ! I was thinking it may explode or something

dose somebady like these ?

I have a few things in mind to reflect the light source to a more concentrated light, such as a soup ladle, I also have a lens from a craft magnifier / work light. At present I just want to get the build to a working state and then concentrate on the tweaks that will improve the overall working result.

Good luck with your build peter cyt.

Took some quick snaps of the triplet focused on the lamp projected onto my fridge door. pretty straight and central.... good stuff

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Decided to fit the reflector to the light box, I used a computer fan holder (wire frame one) and cut the rings out to sit the reflector in, I see this a lot in the forums so decided to give it a go.

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I don't have a photo of the light difference with the reflector to compare yet but I will get one soon and post it.

When I was setting up the prog for a first time alignment test, I knocked the LCD panel off the slot that the back of the panel sits in and the FCC connecting to the panel snapped off the connection has been tempromentle from day 1, whenever I try to connect the FCC to the panel now all I get is vertical blue lines on the display...... I have tried to repair the connection but I cant seem to get it to stay, I guess the panel is no good any more. 1 panel down. The projector build is on hold until I find a new panel...... Gutted!!! but pleased I only paid 99p for the panel.

I have my eye on a nice 15.4 HDMI TV with back light problems on ebay..... I will keep you all posted.

Cant believe I may need to change my design to suite the new panel. I did allow for a bigger panel, in the hope of putting a HD panel into this build as soon as I could find one, maybe this is fate!!!!

Still pretty gutted about the work I did based on the LCD panel I had.

Nevermind!!!! Onwards and upwards.

Don't feel bad at all. I got so ahead of myself on my build that I made the whole box and did not take into account the material thickness. Got it all screwed together and finished. Went to put the sled into it... ....an Inch and a half too small. ROFLMAO!!!

Just breathe deep and laugh.

That sucks man. I know how you feel about the panel. I broke my first one

Also i love your projector design very very sleek.

I would suggest that you consider painting the surrounding metal behind your reflector black.

It will help a lot with keeping stray light down, and will result in better contrast with your projection. You'll have less stray light in the front part of hte projector, and less heat at the LCD panel. It's not an absolute requirement, but it is recommended.

Well !!!!!

I got my hands on a 720P 15.4" HD LCD TV, Grundig GU15WUP. It was advertised on ebay as powering up fine and losing picture after 5 Min's. Turns out one of the back light plugs to the controller was loose, I guess the company I bought it from should have checked this, but didn't bother.

The VGA input on this TV is only 1024X768 which I am confused about as its a wide screen and any computer input into this is viewed in a stretched format, but I am sure I can maybe rectify this with power strip of something similar

I got the TV stripped in 10 Min's and put the back light issue right. I was reluctant to use it for my projector after that as it was then a good fully working TV. I decided to use it anyway as that is what I bought it for!!!

The PCB board is a single strip which I am very happy about, no trouble with LCD sled this time and no FCC to contend with too. The controller is quite big so I have had to make a few changes to the design guts to get everything into the enclosure, but I guess it will be worth the hastle.

I have ordered some new Fresnel's and my FS Mirror which I am waiting on, but I can get a few things done while I wait of the new Fresnel's and mirror.

The controller has every input known to man so I have a good choice of inputs and no limits as to what I can use the projector for, which is a bonus.

I have made the LCD sled and the panel for the controller, I also decided to use the speaker cover in the enclosure as it holds the remote sensor (for all I dont think the speakers will be very good) sure they will be handy for times I use it and need a audio source from it.

I will get some pictures on the PLOG sometime soon.

This is a picture of the LCD TV that I got for £31.00 (absolute bargain)

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So my build is back on I guess.

Picture of new LCD sled.

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Picture of the front of the new LCD sled.

I used the aluminum frame and the inner plastic frame to hold the panel tight and snug in the frame and cut the MDF to the size of the panel frame. This was a hell of a lot easier than the last set up I had on the last panel, when I look back at how long it took me to get the old LCD panel from the 15" monitor to sit well in its sled, it makes me think why I bothered with the old panel at all.

Word of advice for anyone thinking of a starting a build.

Try to get your hands on a LCD panel with a single PCB strip, it may cost a bit more than an old 15" monitor LCD panel, but it saves you so much time and theres less chance of knocking the circuit board when your putting it in and pulling it out of your build.

Another word of advice.

Try and make your build as simple as possible. My build has turned into quite a difficult build as all the hardware is being fitted through the back of the projector, rather than the side, not as big a issue on straight though builds, but a pain for folded designs.

The front of the LCD sled.

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Picture of the controller input board.

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Nice to have a multi choice of inputs, and a HDMI (YUMMY!!!!!)

Picture of the speaker panel in the enclosure.

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Shame not to use this panel, the remote sensor sits in the right hand side. Took no fitting, just so happens it was the exact width of the enclosure inside measurement.

Pic of the panel in the TV.

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lookin good, i did the same thing with my first lcd and made an annoying frame for it, with my new one i just used the built in frame stuff, way easier

Yep, definitely looking good!

Picture of speaker setup.

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