I realized that wood, although works for a lot of people, might not be the best material to use. A electric short in the projector or possibly melting of something could cause wood to ignite. Is it not true? I wouldn’t leave wooden projector unintended, especially for the first few time. Maybe I’m just paranoid.

So I started looking around. How about something like Polyethylene (the stuff that they make cutting boards from). HDPE (for High Density Polyethylene) has 295 deg F forming temp. Nice thing about it is that it can be cut with wood cutting tools, heat formed, shaped and welded. It might be bit heavy, though.

Other ideas?

First impression of the suggested HDPE.........prohibitive cost. If the price of those cutting boards is anything to go by I bet you'd be spending in excess of $125.

Ye, bit more expensive, although not sure that it's going to be $125. I found some prices here: http://www.usplastic.com/catalog/product.a...duct%5Fid=10392

Polypropylene baby

welded

Cool, dude.

One thing you will have to do is paint it black inside (and make sure it does't melt).

Oh, by the way, do you know how to paint it?

I'll do the same, if all goes well.

An electrical short or melting of something could not cause the wood to ignite. Wood is not very flammable. In the absence of a flame, wood has to get very hot before it catches fire. In fact, the temperature has to reach approxiamately 482 deg. F before it will spontaneously ignite.

I challenge anyone to take a piece of plywood and make catch fire by using a lit match.

Thats a little risky isn't it. Do you really want people that spend all thier time reading DIY projector websites to play with fire????

Don't be surprised if there are no posts tomorrow due to burnt finger tips.