UPDATE 01/31/2005 -- new 512N Installed! PJ is up and running!
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OK, so I am a little ways into building my PJ. Someone sent me a PM asking where my PLOG was?? So I will start one.

I'm at work and don't have access to any pictures I have so far. I will post them soon enough.

However, I did use PSP to draw up a crewd diagram of what I am building. Don't laugh. I am not a good artist, not have a good program to draw anything up with.

NOTICE! This Drawing is NOT scale, so don't believe everything you see. The fans do NOT align to the panels the way you see here. They only cover the area of the panels and do not hang over them as illustrated here.

Let me explain the purpose of the way I made the fan design.
1) having a fan mounted directly to the exterior of the BOX will generate Lots-a-noise! I hate noise.
2) Air is not being "forced" over the panels... it's being "sucked".

For those who are into over-clocking Computers (raises hand) know that the basic element for COOLING a cpu is "Forced" air. Sucking the air off a heat sink just doesn't work as well.

SO, I designed a cooling system that is "internal" of the PJ (very low noise) and "Forces" air inbetween ALL the panels. I'll have better pictures to show you this in time.

I also wanted to utilize the Original Face of my LCD TV (Samsumg 150MP). You'll see that in pictures to come. It looks kind of cool (for now anyway).

I will use the typical "swinging" front fres for Keystone adjust, although I will have a device to manually adjust it, and not just use gravity. I was afraid the fan buffeting would cause them to flap around if left just hanging.

The Focusing device "will be" (haven't got there yet) made up of a 4" PVC coupling that rests on 8 small rubber wheels. It will in a sense "roll" forward and backward. I have stripped an old CDROM to use the gears to make a control for this device. We'll see how that turns out.

I will coat the main part of the PJ with Flek Stone.

About the LARGE 6x12 vents. These are your normal AC Intake vents.
- The PJ Intake vent will have a "modified" Air conditioner filter. The HQ ones.... to keep out the dust. Very little (if any) light will leak out of this.
- The Exhaust vent. The Light compartment will have sheetmetal encasing it in a way that very little light will leak out of the exhaust vent.

I'll try to add a few photo's this evening!

Excellent design,
...may have to borrow a few of your design ideas.

I do have an observation, though.

Would it not be a better design to have those 3 fans where your exhaust vents are instead?

This would "pull" the air through your intake, (and cool the LCD, etc.), instead of "pushing" the air in and creating a positive pressure inside your PJ.

Just my loonie's worth


Carl

As Agent707 explained in his post, he is forcing air across the panels, since the greater the volume and velocity of the air moving across the panel, the greater the cooling effect. This is a great idea.

But I think it would be better to have 1 fan blowing in over the light engine side of the LCD and one fan blowing out over the light chamber. Two reasons, the projection lens side of the LCD is not subject to the radiant heat from the lamp and since the bottom of all the fresnels and LCD are open, you might get a swirling effect of air in the front and back part of the projector which would not draw the heated air (from conduction/convection rather than radiation) out of the box effeciently enough to keep the whole box cool. I think it would be better to have air forced in AND forced out of the box with the air drawn in a smooth path across the components that you want to cool.

I was planning on using a slim PCAC fan to blow air into the cooling slot for the LCD and another at the top rear above the lamp to blow air out. That is if I ever get started.

Not sure if I'm right about this but this looks like a great design nonetheless.

Regards..
Ed

UPDATE!
OK, I got some photo's to show now.

I'm pretty close to being done. I've got all the "big pieces" cut/measured/holes drilled....

Let's start with a simple photo. As I stated in the another thread, I built this mostly like a "cab forward" design. I started from the inside and worked my way out.

So, the first thing I made was, the Frame to hold the LCD, Fresnels and XL10.

This will be the frame for the second XL10, Fresnel and LCD.

OK, let's cut a few boards...

You'll also notice I do a lot of "painting as I go". I don't want to get done with it and have to take it all apart to paint it.

The inside is going to be entirely BLACK... so I paint as I go.

Got the main frame going here. Weird looking huh?

Frame for the LCD Panel, Colimator, and Second layer of XL10.

I needed to get some "mounts" screwed into place so I can install/remove components...

Took a LOT of measuring, trimming, cutting... a few trips to the frig for a cold beverage.

The duct work around the "mangled" reflector is Not the permanent heat shielding... I was just messing around here.

Here is a preview of the cooling system. It is unbelievably Quiet! There will be a Thick air filter above it also, so this should be a really quiet PJ.

Here is a better view of what it's going to look like. I still have the "nose" piece to build.

OK. gotta Strip it all down and paint again. Paint - Paint - Paint!

I want to point out the Light mount.

I pieced together some wood to make a mount where I could "slide" the light in and out with ease. It works GREAT! all that holds it in is ONE SCREW!

The back plate has a wide grove cut in it to allow the wires to slide in and out without catching on anything.

OK, Let's do some Wiring!

Hmmm... wonder what I could do with this old thing?

Using an old power strip I got WAY BACK around 1990... (you know, the kind you used to set your monitor on?)

I decided to strip this thing down and put in a "built in" power strip... Also makes some cool lighted switches.

I replaced one of the outlets with a power cord Jack! It also still has the built in 15a circuit breaker button.

The switches say Master / Computer / Monitor. However, the order they work is like this. (and I will relabel them in time)
Master switch...
- Powers on the Outlets in the back of the PJ. (here, you can plug in your PC, DVD...etc.)
- It also applies power to the LCD Panels power supply inside the box.
- Powers the switch labeled "Computer" (fans)
Computer Switch... (will relabel "FANS")
- Powers on the Fan unit.
- Applies power to the "Monitor Switch" (light)
Monitor Switch... (relabel "Light")
- Turns the light on... DUH!
Note* the Monitor (light) switch will NOT work without the FAN switch turned on. Turning the fan switch off will KILL the light as well.

No tempature sensing gear will be installed. I am leaning on my cooling system to get the job done.

Some wiring completed.

OK. I can't wait any longer...
I gotta see this thing LIGHT UP!

Let there be LIGHT! ... and there was light.

Let Us seperate the Light from the Dark. So Agent707 painted everything Black!

Agent707 saw that it was good, and so it was.

OK, enough goofing around with Lights... Back to work!!!

Finalizing the electrical. Notice the LCD Power supply. The power cord is Hard Wired inside the outlet. The only thing the outlet is for is the 12v adapter to power the fans.. (It's a real lug too... a 2.5A adapter)

Cover up the stuff with Galvanized sheetmetal.

I used the cover off the old power supply I raped to get the power cord socket from to make a heat shield for the Transformer.

Just make sure you have a layer of something in between the light source and your components.

Added some more galvanized sheetmetal around the light. This metal was painted with 1200f Header Paint. Why not!!!!

And the reflector? Man, I looked all over town for a mixing bowl. Couldn't find. So I just picked up this colander from JC Penny's. Heck. It's good enough for now. It's round at least.

Now... gotta test that light again.

Slide that puppy in and fire it up...

Just slide it in...

And hook up the terminals... and you're ready to go.

Near Final assembly of Light Engine...

Well, that's in for tonight.

Tomorrow I plan to finish up the light engine. I still have a few pieces of sheet metal to cut (and PAINT of course) and install.

After this, I will put all the panel frames in (minus the LCD) so I can "beam" out the Triplet location and begin making the Nose Piece!

I aint looking forward to that piece... It's going to be a pain, I can already tell! LOL.

It's the Focus mechanism I am not looking forward to make. I know how I "want" to make it, I'm just not sure how I'm "going to" make it.

But at any rate, it should be functional and look OK.

I should be showing Movie screen shots by this weekend I hope!!

Nice PJ very clean design, I really like out annotations to point out features, good presentation. Hopefully you'll be projecting soon.

WOWWW

very, very nice...

realy god job

Very smart looking projector design.
I really like the way you used the front of the TV and the computer control switches.
The colander you used, is it a standard item at JCP?
I have some friends looking to make projectors and will need reflectors.

Well, I certainly wouldn't "go out of my way" to get a Colander if possible. I can't say for certain it is a standard item they carry. I was just walking through the mall with the wife and saw it.

You can give it a try if you don't mind using one. I'd prefer a bowl. Maybe next time.

I had been in every store in town it seems (fairly large city where I live to) looking for something to use for a reflector and was getting tired of it, so I said to myself...
"The FIRST round item I find be it colander or bowl I am BUYING!"

I saw it, I bought it. It was like $15 or something

I had bad luck ordering something online, as when it came in, it had a big Flat bottom!

Good luck with the reflector!

I do plan on replacing it if I "ever" come across something without holes in it.
Of course it will have to have a 3.25" radius to "fit" into my current rig.

[edit]I also want to point out, that I think I trimmed too much of my reflector off. Oh well. Like I said. Hopefully it will get replaced one of these days. [/edit]

Any idea on what a good "Air Filter" material would be? I tried the regular house air filters (the high density ones, not the blue ones), but they create way too much drag...

I may try a "car air filter"... Has anyone tried one of those?

That's Great! I am loving the relatively linear paths of cooling going on there. also the spacing (duct dimensions) looks superb... and the housing is super too... really well thought out.

I realize you have the light engine all set up and installed, but one thing you might consider is putting the vent (out) at the back of your light engine so as to put the path of air across the hot components as well, and therefor also avoiding a light leak. I build a similar light engine to yours, viewable in my plog soon, but my (evercool) fans are installed in the back of that currently. may have to alter that a little now that I've seen your design...

I also have some ideas on adjustability of the bulb position, the reflector, etc.

Too bad I have to work 80-100 hours per week It has been limiting my playing and posting)

What about the fans? make & model?

Looking forward to completion, temp tests and screen shots!

About the fans: Just a bunch of junk ones I had in a box. I have (had, that is... gotten rid of a ton) LOADS of old computer parts. I used to be a tech before I started programming years ago.... so I just try to use what I have before going out and buying.. I just picked out the quietest ones, and in the best condition of the lot I had.

Unfortunately, my reflector is "fixed". I kinda wished I'd attached it to my "slider" mount for my bulb. Oh well...

About "path of air across the hot components": The way the air will circulate into the light box, plenty of air will move in and across all the components in there.. there is a clear exit path to all the ducts leading to the exhaust. It's not real visible in the photos with it being all conjested and BLACK! I will monitor it however the first frew hours.

Not but OOOOOUCH! Man, that sucks. I sure hope you have making the $$$ for the effort. That's like 12 to 14 hours a day 7 days! Go on Strike!

I'll have more pics to put up tonight. I have the "nose" piece about together.. (It's a little LONGER than depicted in the original drawing in 1st post. Looks a little funny.

Hey, about your air filter. I use a cut to fit foam room airconditioner cloth that I got from the 'Big Brother Corporation'. Ahem.... I mean Wal-Mart. I also built a small rectangular box that fits over my intake slot. It's about three to four times the width of the slot and stands about two or three inches off of the top of the box. Instead just laying the cloth directly on the slot. That will really improve air flow while using a filter.

I think I found some stuff to filter with. Cool.

Got a few new pics. Almost ready to project. Should have it fired up tomorrow night.

Basically done... just need to clean and screw all the lenses/panels in and hook the pcb's up.

The exterior is just a ROUGH finish... That is NOT the final finish of the PJ. Just some primer to hold me over for a while. I will eventually fill and smooth all the joints and give it a final paint job. Thinking about fleck stone, but not sold on it yet.

Got the nose piece roughed in...


Got the nose piece all prettied up with gray primer.


Looking down it's throat


The controls... all video inputs (except component), lighted power switches... and a few extra outlets to plug your accessories in with.


The intake and exhaust are just 6x12 air vents... there will be ducting under the exhaust to block the light. Very little should leak out.

BTW, I will get around to painting the vents "black".

Get the popcorn going!!


Hopefully I'll be posting some projections by this weekend.

Looks nice, a bit more interesting than the shoe box look that is so common.

Kinda reminds me of the Imperial Walkers from the StarWars movies, just needs some long legs and little people shooting at it with lasers.

nice box looks like a old polaroid camera

<<Imperial Walkers >> <<polaroid camera >>

Well, I really wasn't going for that "look", but now that you mention it.

Please don't shoot my pj with lasers.. I've worked so hard on it!!

hehe

Very innovative design .. cool looking PJ ..

One thing though .. those 3 60mm fans can be very loud in high RPMs so you might want to plug them in a separate fan controler to adjust the speed and control the noise that way..
or you have a spare 9v or even 7v wallwart with the right Amperage you can use that instead..

Great job again.

Trust me, they are MUCH quieter than a typical 100cfm 120mm fan. I have several of those laying around, and just one of those is a LOT louder than all 5 of these running on 12v.

Also, it has a nice sound to it. Not just a single pitch sound you get from one fan, but a nice little "humming" sound in multiple frequencies. Kinda like when you walk into a server room (without the db's).

Thanks for the compliments.

I hate server rooms..

[massive fan noise]WHAT DID YOU SAY??? Speak up! I can't hear you! [/massive fan noise]

Seriously, I have been in a few that SHOULD have a sign on the door. Warning! Ear Protection Required! :angry:

But compare that sound to what a "single fan" that is twice as loud would sound like! (Like a 4" diameter, 30,000 rpm hair dryer I suppose). That's the kind of compasison I'm talking about.

I'm out of commision. My LCD doesn't work any more.

While I was mounting it to the panel frame, I chipped the corner of the glass. I don't know if that's what broke it or not. It doesn't look like it did much damage... just chipped the corners off. (chipped 2 corners actually).

None the less, it doesn't work.

Monitor comes on, but is just a big smudge...

Oh well. In the trash it goes.

Perhaps I'll be back in a month or two if I get another panel.

Cheers..

I know how you feel, unfortunately. Hope to see it revived someday.

Holly sheet...

Sorry abaut that.

I’m really anxious to see you PJ complete...

You are doing a really god job.

Well, I guess it’s like life, we fall, and we must get up again, and continue…

Try to sell the circuit board, and make some money…

D'oh! maybe you could still do temp testing on your box... that way if there are any problems (not that I think there would be with your setup) you are not burning up a good lcd. And you could try running fewer fans (by unplugging them) and simulate fan failure/requirements.

Hope you are back up soon

Well, as it turns out, there is hope. My kind and generous wife told me this morning she would buy me a new monitor. What a sweetheart!

The big question is what to get... Another 150mp? Or a 512N?

I could pick up another 150MP off ebay and continue on with what I have... or I could go TODAY to CC and pick up a 512N?

I like the setup with the 150MP (have the PJ all setup for it with the face plate and all ya know)... however, the 512N does have way better specs...

Check out your other thread for my other input. Personally, I couldn't wait for a new one to ship.

*putting shows on now heading to Circuit City to get 512N*

I'll update this evening!

God! I love my wife!



Well, here is the REAL scoop. See, I really strapped myself for cash after the wifes Birthday.. I had budgeted JUST enough money to build this projector...
hehe, It usually takes me a few months to recover after the first of the year.

Dec 25 = Spend Lot's-o-money for me.
Jan 13 = Wifes Birthday = Spent lot's-o-money this year on her.
Jan 22 = My Birthday (yea, last Saturday... the big 42! )

So money pool is low on my end... (not the wifes... she doesn't believe in it. LOL)

So anyway, she went ahead and calculated our tax return this morning. As it turns out, we're going to get a nice one this year (~$6g). So she said, what the heck, I'll buy you a monitor!

Now, where was I? Oh. Off to the Store!

Well, just got back from Circuit City. Got the 512n in hand...

Stip down time!

Not a bad deal. $249 with $70 in MIR's = $179. I'm happy. Hopefully this thing will go in without too much moding of my PJ.

Wish me luck!