Re thought wiring extension today,had 1x 8pin and 1x 9pin cables to extend.Found an old parallel cable,enough strands in there to do both in one cable.Wish I had done them separately now,but its too late now.Not entirely sure if it will work,as I started seeing double about half way through.
Soldered cable,needs tidying:

And detail of one end:

I think I might have pushed my luck one step too far on this one,thats 17 soldered wires at each end.I am going to put it to one side for now,and check it over tomorrow,because I cant look at it straight anymore!!

Reminds me of the cable I once soldered, years ago when I got my first Amiga I needed a 50pin harddrive connector to 25pin D connector cable, couldn't afford one so I took a normal 50pin SCSI harddrive connector, some 50 line ribbon cable and soldered the necessary 25 lines of the ribbon cable to a 25pin D connector, amazingly it worked first time and for years after!

If you're not using the audio on the control panel you can do away with the cable that has only 8 wires on (the one nearest the end of the panel), my identical Benq is connected with just the 9 wire button line and works fine.

AAAAAARRRRGGGGHHHH!!!!!!!!!!
I actually soldered the 8 pin connector using a piece of cat5 cable I had lying around,yesterday.I unsoldered it and used the parallel cable to incorporate the 9 pin !!!!!!!
I will remove the whole cable and re-do using the cat 5,it was more flexible and alot neater(but it can wait till tomorrow).What a wasted afternoon,but what the hey,I could do with the soldering practice (NOT).
Cheers Haku,my pj will be a neat and tidy place thanks to you!

Love your plog Punisher, you've really done some great work here. I want to extend some wires myself and I wonder what you have in mind to insulate the connections after soldering? I was thinking heat shrink tubing but that has to go in before the connection is made. Do you plan to use the paint on insulator or wrap each one in tape or something else?

Yep, as of this morning my projector is fully operational.

Your box looks incrdible, loving the rounded shape and the time you're putting into its finish and appearance. I'm very impressed with the Punisher design in your mirror holder - you have far more patience and attention to detail than I could muster.

Hi,guys.
Thanks Deathray,
Your input around the forums is incredible.Ideally I would have used heat shrink tubing,It would make the job,quicker and easier.But alas,the only one I have found among all my bits and pieces has a diameter way too large.
The plan was to wrap each wire in a small piece of electrical tape,then wrap the collective wires in more tape.
Considering I am going to re do the whole thing now anyway,I might wait and try to get to my local model shop and pick up some of the correct diameter.
Given the choice I would go for the heat shrink tube every time,it is neat and tidy and makes the best seal.

Cheers Kocmoc,The more important difference between our pj's is.....
Yours is working and mine is not!!
Yours is a fantastic design,functional and practical.
Mine is effectiveley the same principal,I just decided to alter the shape of the box slightly.
PS pics,pics,pics!!!

Man! I'd go nutz trying something like that!!! Hope it works out for ya!!!

Cheers tj,it proved to be a complete waste of time!!!!
First I made a cable for the 8 pin plug.
Then I made a cable for both the 8 and the 9 pin plugs.
And now,thanks to Haku,I have found that I don't need the 8 pin plug at all,as all it does is audio!!
So,onto the third attempt to extend the control panel....
I cut down a patch panel cable,soldered all 8 wires,and added a single wire to run around the outside.Taped each wire with electrical tape(I only had yellow.)Then wrapped each end in shrink wrap tubing,to secure it.

Here you can see the yellow tape wound around each soldered joint

This is the same cable with the heat shrink covering the taped joints.

Finished cable,I will get some black electrical tape and secure the single blue wire,to avoid it catching on anything.

Very nice, and neatly done.

I've personally found the wonders of silicone conformal coating. No fuss, no muss, and perfectly insulated PCBs, solder joints, or anything else you want insulated. Basically it's an aerosol spray can. Works wonders. It is also just the ticket for making your control circuit boards static-proof, now that they're no longer in that nice metal casing on the back of your LCD monitor.

Heat shrink tubing is better for the whole thing, because it's tougher, and can bind multiple wires into one nice neat cable. In any event, the result that you have now is excellent. A bit of vinyl tape to tie in the extra wire, and you're good to go!

We'll see how your box looks after another application of sanding and paint... Just don't use the belt sander for finish work!

Women and Chocolate. The mystical combination of bliss and carefree being. All married men should have a secret stash of the stuff...Brightly labelled " In case of Wife, Break out generous portions"

Hope you had a good birthday!

Hey Punisher, how much space do you have between your lens assembly and the walls of your enclosure? How are you attaching the threaded rods to the base?

I'd love to see a picture of the lens assembly inside of the enclosure.

tmproff.Hello!
How much space between the lens assembly and the walls of the box.....
NONE,not even a mm!
I am not going to attach the rods to the box.The whole "image bank"(I love that)
is completely removeable.Well that is the plan at the moment,anyway!!!
I took a couple of pics with it all in there,bar the optics/electronics etc.
Hope this explains it...


Hope this helps.
Samurai,many thanks,
I am now officially OLD,at 37.According to my kids,anyway!!!

Yes, but I do have one piece of wisdom for you. "You will always be funky in your own mind."

Someday you will dance an old dance at a wedding and the kids will look at you like you have three heads. Who cares? Your still FUNKY! The older couple next to you doing the twist to "Whip It!", well, even they are funky!

Get funky! Stay Funky!

* DISCLAIMER*
Samuraijack turns 40 this December and is probably trying to convince himself to be okay with it. Your results may vary quite a bit. Side effects may include a wife, children and an inability to make it through any show that starts at 10PM without going to sleep.

I turn 29 in 2 weeks.......Just finished college, single, no kids....


I went to the 10:30 PM showing of Kung Fu Hustle last night and I'm about to pass out here at work......

Oh,I've just noticed that I put 37,my finger must have slipped,I meant to type 27,ha,ha,ha,ha,ha...You are all OLD,ha,ha,ha,ha,ha.(cough,cough,splutter,splutter,wheeze,wheeze!!)Yeah RRRIIIIIIGGGHHHT!!
Hmmm,Samurai,Women and chocolate.....Now where did I put that tub of chocolate body paint!!

Supra,that silicone coating spray sound awesome.I have never heard of that!Sounds pretty useful though!!
Need to get my s**t together this week.Need sand paper,LOTS of sand paper.

MG Chemicals website for Silicone conformal coating

It is really cool stuff. Great for those of us who make our own circuit boards. Eliminates danger from static electricity, short circuits due to nearby metal objects. Especially useful for those of us with children who like to drop coins into things.

For your optics assmebly, I'd recommend at least some sort of fastening to the cabinet. After all, it's an expensive touch if somehow it gets knocked over and the LCD shatters. (Not that mine would survive a fall from it's present altitude!)

Cheers Supra.
The optics will be siliconed in,but the actual "image bank" (I still love it!),is wedged in,no movement there,it is a VERY tight squeeze.The tightness of the fit is in fact what I am depending on for the lack of airleaks throughout the system.
I think that so far,I have adapted my design as I have moved foreward,unfortunately,the further foreward I go,the harder it is to adapt the design.As it stands at the moment.I think my best bet is to finish it to current spec and deal with problems as they arrive.I am pretty much expecting to have to change the evercools,which will be a shame,but no real problem.And I may have to think abit harder about the airflow/sealing of the side panels/general complexity of airflow path.But it is pure conjecture at this stage,so I'm not going to worry about it!

Samurai..My brother in law has just turned 40,and he has twice as much hair as me! At least,on his head!!

Your projector is looking absolutely amazing. The way you have mounted the sidepanels, the focusing mechanism ect... ect... Man I can't wait to see it finished. I've been trying to figure out your cooling path and it's not real obvious at this point but I'm sure you've got something figured out.

That silicone spray looks like some pretty neat stuff, hopefully I can get some of that at the local electronics supply shop.

Hey if everybody had heads as gorgeous as ours, we wouldnt stand out nearly as well. Ask me sometime how baldness in human males is basically the equivalent of being a silverback...

Actually, I dont think Im losing hair, I think its just broken free and has headed south! ( yeah, I know, OVERSHARE!!!! )

Supra the conformal spray looks awesome! That really beats the hell out of the "liquid Electrical tape" I sometimes use.

Punisher, you mentioned possibly changeing the vercools. Have you gotten a temp reading that would confirm that? Or is this a matter of sheer airflow?

Samurai,I am only judging the evercools on other peoples experience.From what I can gather,they struggle a bit with restricted air flows.That is just what I have heard,so I am not going to act on it until I can verify it.It is interesting to note though,that if I have problems along those lines ,I know peoples experiences from the plogs have sugggested that the evercools maybe a contributing factor.One day,the ultimate projector shall be born,it shall be the b$$tard child of everyones combined knowledge on these forums,and it shall get up and dance infront of us,wearing nothing but a peanut butter G-string.OK,goodnight,very tired all of a sudden.mmmmmmm peanut butter G-string.....

Hey, just thought I'd throw in my two cents, this silicone conformal coating sounds really useful, but a quick solution for those small wires is to just use a hot glue gun. A little glob of hot glue is really good for making sure nothing short circuits with a big heat shrink around the whole bundle. Just an idea that will save you a trip to the hobby shop if you already have a hot glue gun as everyone should.

I had heard that and figured that to be the case. My fish tank runs a design a lot like that. It is very dependant on free flow. The design I came up with uses squirrel cages, since I think I am going to be depending on negative air pressure. A friend saw me looking at the evercools and mentioned that he had seen a 110 volt version made of metal. He works in ducting and cooling. He also mentioned something called an "Airscrew".
By the time I got past all the seriously bad puns and innuendos in my head I forgot to ask him what it was.

Peanut butter g-string? Hmmm...But will it be "funky?"

WOW.those airscrews are "cool"

I think these are used for cooling Trains and stuff,a bit too serious for us lowly DIYers.I am going to go with the evercools.If I need to change them,it shouldnt be a problem.

I can't wait to see your projector finished either- the entire design is original, clean, and modular. (As an engineer, I am thoroughly impressed by all of these aspects)

I'm also curious about your airflow path. You've obviously got something planned out there, but it's lost on me. If you get a chance, I'd love to see how you plan to work the cooling path.

I think he may have meant something a little more simple than those. Damn those are cool! I was thinking about the pressure differentials. If you made a path you could use one evercool to push and the other to pull. Im sort of leaning that way with mine, except I think I am favoring squirrel cages.

Just a thought

Hi,guys.
Kocmoc,here is a rough diagram of the proposed airflow in the pj.

Hope it makes sense.The main intake is overly large,so that I fan filter it
without putting the fans under excess pressure.
Here is a pic of the mounts:

Like I said,I hope it makes sense.The design of this pj has been rattling around inside my head for months now.I know exactly what I mean,but I never know if my ideas are translating into words and pictures very well!!!

Also,just to show you that I havn't been idle....
This was the box painted:

And here it is sanded

Next I painted it white!!!
Nice white matt emulsion,thick,dries quick and is cheap.

And it sands very well.After sanding this down,it gives a really good idea
of where the dinks,and scratches are:

This pic of the back of the box,shows the battle damage caused by using
the belt sander:

I will need to repeat this process several times,to build up the recesses in
the wood,then I will start spraying!!

Thats pretty neat. Perhaps a slower 80 MM fan to help the flow along? You could place it in back of the input port you made. Maybe use a coolermaster with one of the variable speed controls on it?

Too serious for us lowly DIYers?? NONESENSE!!!! PMan you need at least four.....no SIX of those bad boys in y'er case!!!!

MORE POWER!!!!!

This is the bit that is going to take the time,but be worthwhile in the end I hope!

Just have to say..damn you're a patient guy! most of my projector was built in a week because I wanted to finish it quickly and the image isn't 100% in focus throughout, some of the right hand side is a bit out of focus and the bottom right corner won't focus properly - but for films it works well. I put a shout out asking if someone was going to Ikea and tomorrow a pair of those soare napkin rings are going to be posted to me so then I'm going to take my projector apart and have a go at aligning everything as correct as possible. I also built a simple stand to put it 3.5feet up in the air, it just holds the back whilst the front is held by a normal camera tripod and works well to adjust the height & keep it rock steady. (hmm I should be posting this in my plog but yours is more interesting )

I love the sound of that of that mount,Haku.Sounds like a good idea!
Although I am taking my time,I can't see any reason why my results will be any better than anyone elses.I am fully expecting to have to do a lot of tweaking too!!

raihenkhan.Welcome.
Actually,while re-making the box,I managed to get the height down to 630mm,the width is 345mm,and at the top,it is 335mm deep,and at the bottom,it is 390mm deep.
These are external dimensions.
I will get to work on some decent plans,when I get the time.(my paint skills are non existent! so you may have to bear with me and squint and tilt your head a bit!)

-*
I just updated my plog with a (very poor) picture of the stand I made, might raise the back bar a few inches to help with alignment (keystoning doesn't work very well at all )

Hope you dont mind me replying in the plog,raihenkhan.
I am thinking that it maybe of use to others too.
I am using a 15" lcd.(the benq 567s ver2)
I am using the full lumenlab lighting kit which includes lamp,lampholder and electronic ballast.The pc psu is pureley to power the fans,fan controller and focus mech motor.
I did start with a more triangular shape box.But after building it.I wasnt happy with the size,and realised that I could get it a bit smaller.And as it will be directly infront of me,I thought that if I could get it any lower,then it would be worthwhile.
The principal design is identical,it is just enclosed in a slightly different shaped box.
The dimensions of the box,are all worked around the lcd and frame.Every thing else fits around that.
Hope that helps,dont hesitate to ask me if you have any more questions.If I can help,I will.
Cheers!

pun15her you must be the only forum member to not have even sneaked a look at how your projector is running! Your patience is admirable I will be watching on fire-up day!
Im currently doing the prime/sand/prime/sand etc at the moment..tiring but the result will be well worth it..
BTW what final finish/colour are you planning for your box? (apologies if you've stated this already in your plog..(i have little to no short term memory)

No probs foxy,You get out what you put in,I reckon!
I am not too sure about colour at the mo.
I am leaning towards white!!!
Very minimalist!
Although,being a big formula 1 fan,I might even go with a BAR theme of white black red and green!!!!!
To say I havn't sneaked a peek is not strictly true,I watched a few music videos holding the triplet in one hand and a mirror in the other,I dont think that really counts though,does it??

raihenkhan,
I am quite happy to give measurements that detailed,no problem.
Its going to take a while though!!
I have no images yet as I am still building!
I will publish exact dimensions for the build.And am quite happy to supply a complete building guide.(to the best of my ability)All items used ar readily available from hardware stores across the world.
The nature of these forums means that,just as I have been able to make my pj,based on the expertise of others.I am happy to help all I can and will gladly answer all the questions you can throw at me.It may just take a while.
NO PAYMENT NECESSARY!!
BTW: where are you in the world??
PS would you mind if I quote your PM message?
PPS you can reply and contribute to the plog,your input is a part of the building process and will be helpful to others,too!!

Hi Pun15her.

I've been following your plog since I bought the plans three weeks ago, partly as your PJ is looking so damn good and partly as i'm just along the road from you in Hove.

I should be starting building my PJ within the next month or so and plan on getting the lense,fresnals and lighting as you did from LL. Could you tell me how much it cost you in total for purchase and shipping?

Cheers. Can't wait to see your results btw.

Hey,you live in hove,cool!

Bear with me a mo,I am just going through my paypal account.
HOW MANY PAIRS OF SHOES HAS MY WIFE BOUGHT FROM E-BAY!!!!!!!!!!

OK.Lighting kit all in was $200.75,which was £106.97,in march.

And the lens kit was $88.98,which was £48.24,last November.
Hope this helps.
These items can be gotten cheaper,elsewhere,but buying from ll means you know you are getting the best product for the job,plus the service is faultless!!
If I can help,let me know.If you want anything,I have some surplus stock.A temp monitor,fuse holders,some cool switches.Got my glass from lancing,not far from you.
All the best

Oh hey I forgot to say thanks for your closeup pics of the wire extension mod you did - really helped me out in a jam, I snagged the cable on mine and 3 wires snapped, using your pics I was able to tell what wire went where

You have a spare fuse holder? my lamp is still running off it's own plug separately from the fan PSU.

Glad to be of service Haku!!
Yeah,I bought 3x fuse holders from our friend maplins.Surface mount,just screw to a piece of wood,solder your wire ro each end,and Bobs your uncle,take standard 20mm fuses.
If you want one ,just pm me your address and I'll send you one!

Thanks Pun15her. Thanks that's a big help.

I'm actually in Portslade so even closer. No doubt I'll call on your gained experience for assistance. I'm so excited by this project I feel a bit sad. The day I bought the plans I didn't actually sleep as my brain wouldn't stop thinking of ideas

I've got a couple more quick questions.

Are your fresnals attached to glass or just mounted in the frames on their own?

What's the name of the glass shop in Lancing you used?

I've got to build a ceiling mounted PJ. Anything that's going to save weight is preferable so I'm thinking of using polycarbonate (lexan) instead of tempered glass. If I'm only going to need one piece for the heat shield I may go glass.

Thanks.

As I have gone vertical.I have gone glass,with fres resting ontop.One piece on rear fres,one on front fres.Hopefully this will resist warping!
Brooklands Glass centre
Western road
Lancing
01903754002.
I think there is a specialist plastics shop at the bottom of portslade high street???
That could be a useful scource for help?
BTW,I am going to:
Sackville Trading Estate
Sackville Road
Hove
East Sussex
BN3 7AN
Tomorrow morning,Is that anywhere near you?

I know the plastics place. I pass there quite a lot. I'm not going to start with those bits untill I physically have the lenses and LCD. My first PJ will be similar to Hass design. I may build a vertical for a friend after that if all goes well though. So you haven't stuck your fresnals to the glass just let them rest on top?

Sackville trading estate is about 3 miles East from me. I was there a couple of days ago studying Focus DIYs stock for parts and inspiration.

Hey cool,no I havnt stuck them,I will see what happens when I "flick the switch"!
I have to go to the optical lenses factory opposite Focus tomorrow am.

Rainers! One of my best mates works there. He's the one I may build a vertical PJ for. He was going to buy a projection TV but I've persuaded him to hold off for a bit. I've not managed to convey to him just how impressive these projectors are going to be. I'm sure he'll be begging me to build him one once he sees mine though. He is a huge movie fan.

WOW,small world,I look after the computer system for them!