Hello all. I have been here for well over a year now, and have accumulated enough parts to build 2 projectors, but haven't really started either of them. I've been as committed to building this thing as a kamikazee on his 35th flight............
I have parts for a 15" or smaller, and the PRO setup as well. I plan on making a small PS1 with the S15 kit, but that is for another day.............



For this PJ - I finially decided on the design. I had been hee-hawing back and forth on what type of design, folded, not, vertical, horizontal, etc. I have decided for simplicity vs size sakes to go with a horizontal fold.
It will end up looking something like this: (dimensions are NOT necessarily what mine will end up being, but hopefully close)


I had also looked at using this design pattern, but in a vertical form, but for the sake of actually gettting it done, i went flat!

The parts that will be in this PJ are as follows:

 -- SGI 1600SW
 -- Pro Kit from LL Store (already have the old one, just waiting on the new triplet)
 -- Original Ultimate Light Kit from LL store (S400DD lamp, E-ballast, mogul)
 -- Lexan XL10 for heat shield
 -- Ikea Soare napkin holder for reflector
 -- 1/2” Birch Plywood for enclosure bottom and sides
 -- 1/8” Hardboard for enclosure top (keep weight down)
 -- Currently 1 Evercool PCAC fan (may change to 120mm, or add another)
 -- Aluminum Flashing for Lamp area
 -- Many misc things not worth mentioning………


Since I am using the SGI 1600SW monitor, i had some issues to figure out. First, the lcd has controller boards all along the side and top. This meant keeping it in the frame would make it MUCH easier to mount, or so I thought. Inside the frame, the LCD is offset to one side almost 1/2", but not exaclty ( it's like 15/32" or some dumb number like that). So to mount it and keep it centered, i used a 1/8" hardboard piece that i could use as a frame that would make the LCD center when I mount the LCD to this off center, if that makes sense. This eliminated any need to cut the fresnels off center as well (allows for use later if smaller, higher res panels become available). So to make a Sled, I made it a couple inches wider than the LCD frame so i could center the LCD. However, this did make the two FFC cables that extend from the LCD to the controller boards a little problematic. Because i am making a fold in the light path, the LCD has to be flipped around. Thus, the controller boards are on the lamp side. after MANY hours, and thinking (read hitting my head) - i decided to bend the FFCs more, and make the boards on the front side still. this requires the FFCs to be bent a LOT, but once situated, I hope they still behave themselves and give me the picture I'm REALLY looking forward to. There are a couple other SGI 1600SW PJs out there, and they rave about the PQ - So I have my fingers crossed, tightly!!

I will be using an 'Unsplit Fresnel' design, to retain the PQ as much as I can. This will not allow for keystone, but the PQ will make up for it. Plus, withe the PRO kit, I'm hoping it wont be as big a deal, anyway.

Here is my sled design, mocked up, not put together yet:
Click to view attachment
Click to view attachment
(ps - the tape on the LCD is to help alignment)

You will see the supporting panel in between the uprights is up off the ground - it is approx 1/2" up to allow for airflow. This board is also approx 1" away from the LCD. The Fresnels will be placed right after this 1" to allow for proper airflow. The board will hopefully allow for not only alignment for the sled, but also keep the airflow moving to the light chamber, and not getting slowed down by turbulence because of the gap between the Fresnels and the Lexan heat shield that will be a couple inches behind. I hope this makes sense....

To hold everything in its place, i will be using this plastic channeling to have the LCD hardboard frame, the Fresnels, and the Lexan heatshield slide right into place from the top:
Click to view attachment

I plan on having three of these mounted next to each other along the uprights of the LCD sled to allow for a couple different mounting locations for the Lexan and Fresnels. The outer channel will hold a 3mm sheet fine, and if that isn't the right location, the middle channel will hold a 1/2" hardwood just perfectly snug that I can route a channel into. (Many options!!!!)

I hope this makes sense to everyone, thus far. I have a LOT more to do, and more pics will hopefully help ppl understand what I'm trying to build. It wont be done 'fast', but hopefully, God willing, it will be done 'right' - at least as far as PQ is concerned....

Here is the back side (the side that will face the mirror and triplet):
Click to view attachment

As you can see, the LCD board that attaches to the LCD will be in front - I will have to make a sled for this board and the other that the SGI uses, but that should be easy enough.
The 1/2" MDF on the top of the LCD doesn't 'need' to be there, but I'm hoping it will help with light leaks into the front, as well as airflow!

More to come.................

Yes Ive been waiting for your Plog too .If im not wrong you will be the first to make such a PJ based on this design. Looks great.

OK, did a little more tonight. The LCD sled is built up, not counting the channels. I cut it down a little to make the box a little smaller (it's large enough the way it is).
here are some pics of the layout. Used some left over pieces to makr where things will go, and the approx size. - this is set up on what will be the bottom (floor) of the PJ. It is a 48"x~23" sheet of 1/2" birch ply.
Click to view attachment
Ruler for general size reference

This is the front half for light path off FS mirror (1/8" harboard mockup) to the front where the PRO Triplet will be located.

Click to view attachment

What I still need to spend some time on is the actual distance for the mirror from the LCD to make sure i get the entire light path. I'm gonna use my laser level to double check light path. Since i'm going to use an unsplit design, it will come from behind the lcd.

That's it for now - stay tuned for more tomorrow - if I'm lucky, i'll get this done by Monday Night Football -- MN at GB (i'm a Packer fan in MN - scary, but hopefully the HD will help win over some of my Vikings fan friends to come over and watch them lose!!!!!)

god bless a fellow pack backer

its been a rough year

that atlanta game was something else

i think we will get the viks, tice is a moron




oh yeah sorry to hijack the thread


nice box :0)

lol - no problem - One of the resons for this is to watch them actually WIN - hey, maybe my delay in construction has been the reason they haven't been..... hmmmm

Gotta get on that!!! (altho i DID record the Saints game in HD - now THAT was a whoopin!!!!)

BTW - there will be no Tice this game, i believe - moron wasn't paying attention and got taken out by his own player pushing the guy out of bounds!!

OK, Back to topic...........

Hi,
I see that it's been a long time since you've added to your plog. How is your project coming? I would love to see the finished product.