My last projector was a fairly decent success. It was very similiar to the Haas design, with a few of my own modifications. It did have a few downsides though. The sliding panels would always tear at my foam insulation when I installed or removed them. It also seemed too much trouble to open the projector up. I had to remove the back panel and leave it dangling by the wires while I tried to carefully slide out the bottom panel. I also experienced splitting with my laminated pine, caused by the heat from the bulb. Other than that, it's an awesome looking projector.

So, I've decided it's time to make another projector. This one will be very similiar to the last. I have removed the sliding panels from the design however. Each panel can now be removed with 6 screws, 3 at each end. I could probably even get away with 2 at each end. Removing the slots used by the sliding design also means the projector can have a completely smooth surface and the side panels can be shrunk down in size a bit. The projector will also be made mostly from 1/2" MDF. This will ensure that I don't have to go digging through the lumber pile at the store trying to find pieces that look good and aren't warped. I'll probably go with a 2-tone black gray color scheme. Gray top and bottom panels and black everything else.

One goal I have for this project is to come up with a design that is highly cost effective as well as easily reproduceable. I want to limit the number of parts and the complexity of each part. I'm going to use the CMV 520D because it is widely available. With any luck I'd like to be able to produce complete kits for others to purchase. I'd like my kits to take the guess work out of building a pj, for those who don't have the tools or know-how to do a lot of the work themselves.

Anyway, here's a picture of an early prototype. This is more of a concept model. I'm using it to help me fill in my SolidWorks assembly. I'll be cutting new parts for the first working prototype, so this box will probably end up in the fire pit.

This model uses a 110cfm 120mm 110v fan along with a metal grille. I'll probably also design back panels to accomodate Evercool fans as well as 80mm fans.

You can see in this pic I haven't angled off the end pieces yet. The end pieces are supposed to be cut at an angle on the top and bottom to match the curvature of the box.

And yet another...

It is almost the same as mine but mine has groove on front and screws at the back. This way will be easier to remove the covers.

I thought about doing that, but then the front panel would stick out making the pj look lopsided. Do you have any pics of yours? Can't seem to find any on the forums...

Sorry I don't have any pic taken yet. I am planning on taking picture when I am ready to put everything together. Mine is bigger than yours though. My main concern about building this proj is not the size but it is about keeping it cool and safe to operate.

Looks like a very clean and fresh mod from the Haas

Great modification on the top panels. I am tempted to build another PJ, but the memories of building the first one are still fresh enough that my enthusiasm to rebuild it has waned.

Any progress on your new PJ?

The prototype is half finished out in my garage. I just need to cut the frames for the lcd and lenses. I've been out of state so far most of the summer, and I'll be leaving again on tuesday. Hoping to get an image by this weekend.

I'm back, and Pulsareus #2 is now projecting! You'd be amazed at how much easier building the pj is when you have it completely modeled out before construction. I'm just waiting on my FFC extensions from mouser so that I can finish assembling the pj and get the wiring taken care of.

Lots of pictures to come shortly...

My 6" 30 pin FFC extensions arived this morning. I can now mount the 520d control circuitry where it belongs. Here's a picture with the projector laying upside down. Everything is looking good so far.

The projector is finished for now. I still need to get it painted, but other than that, everything has turned out very nicely. It doesn't have the nice grainy wood look of the last one, but this design ended up being so much easier to work with.

The image created by this projector is much brighter than the last. The focus seems significantly better as well.

And for any Naruto junkies out there...

Naruto = !! Rocks!!

The test image looked very nice too, very bright, all the way out to the edges!

Nice work!