Well, it is time to start my 2nd PJ. The first one I built was just to get a build under the belt knowing that after the build and using it for a while I would have bigger and better ideas and a better understanding of what I wanted. I completed everthing on the 1st build except for the lid which is still cardboard. I made the fatal mistake of firing it up before completion and decided the cardboard lid would due because I was having more fun watching movies. If you are interested here is the first build. BoomerBrian's PJ #1

I will be using the same parts from the 1st pj for this build. The only thing that will be different is that I will be removing the antiglare from the lcd.

Parts:
Standard LL Lens - Lumenlab
S400DD bulb and ballast - AtlantaLightBulbs
CMV 520D 15" LCD - Used from jcrakcorn
Ikea Napkin Reflector - iReplica.com
Lexan XL10 - Home Depot
Thermaltake 120mm fan with speed control - PCClub
Aluminum, wood, and other misc. parts - Home Depot


I wrestled around for a long time with the design. I knew I needed to go vertical because I needed the PJ to be able to sit on the ground and be moved around. I almost went with the Pun15hers design because it is a classic but decided to try something different. The last house we owned was a 1920's California Bungalow. So after living there for a few years I really grew fond of the Art's & Crafts, mission style furniture and thought that it would also make a great PJ. When the PJ is not in use it will probably double as a side table.

Here is a cardboard model of the PJ. I like cardboard models because it gives me an idea of size and scale. There is going to be much more detail in the PJ but this will give you an idea of the shape.
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Here is the PJ next the Pun15her cardboard model.
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Go Go BoomerBrian!
Looks very nice,I love the shape.I think that will make a cool pj.
Just remember to make a lid for this one!
Best of luck,P

Thanks Pun15her for the comments. The lid will be completed on this one. It is going in the living room so it must have the wife approval factor.

I built my fresnel and lcd frames out of 1/2" mdf. I first ripped 2" stripped on my table saw.

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I then routed the 2" strips with my router table.

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Here is a picture of the frames put together. I decided this time to use the metal lcd frame that came with the monitor. This way I can make sure the frame fits the lcd nice and snug.

Lcd frame with the metal frame.

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Fresnel frame.

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Since the frames are 2" wide I will probably cut 1" of each side just to make them smaller. Not for sure yet. It really depends on how they fit in the pj.

On my first pj the fresnel frames were larger than the lcd frame.

On this one I made the fresnel frames exactly the same size as the lcd frame. I will probably be tilting the triplet around 10 degrees so I will be doing some keystoning. I didn't really think about this until after the frames were completed. Will this cause any issues like dim corners or will this be OK? Below are some pics.

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As you are keystoning,and using a split fres setup,you can have the fresnels the same size as the lcd.With both fresnels behind the lcd,they need to be a little larger as the lightpath starts to converge before the lcd.

Good work on those frames.The smaller you can get them,the smaller enclosure you can build.That is always one of my main design considerations,you can always build a bigger box,the trick is getting it smaller.
Cheers P

Thanks for the answer Pun15her. That is what I wanted to hear.

Well I finally found some time to work on the PJ. Today I got the front and back of the box made.

I decided to build the box with 1/2 mdf. I wanted to cut down on weight and I like the way mdf mills. I am either going to put oak veneer over the mdf and stain it or paint it since my wife likes painted furniture.

The first thing I did was lay out the measurements on the panel and then I screwed the front and back panels together to ensure that they would be milled identical.
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To cut the angles I used a scrap piece of 1x as a guide for my skillsaw.
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After cutting the sides now it is time for the arc on the bottom of the box. For this I made a simple jig for my rotozip. I screwed down both pieces to the table to make sure nothing moves during the cut.

The distance from the rotozip blade to the screw used as the pivot point is 16" and on center. The tallest point of the arc is 1 1/2" from the bottom of the pj.
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The jig worked out very well. It made a perfect cut. Wheew. Here is a pic of the front and back. Click to view attachment

Things to do next:

1) Make to top.
2) Make the bottom.
3) Make the sides.
4) Add Mission detail to the front.

Possible detail ideas:

Since my goal is to make this look like a piece of furniture here are some ideas I am working on.

1) Mission style fan grate for the fan intake opening that draws air in across the lcd.

2) Custom made Mission style stained glass flap that will lower when the triplet comes out for projection and raises back up when the triplet goes back in the pj when not in use. I am planning on motorizing the triplet so I would like for it to be hidden when not in use.

Loving the shape of the panels,A blanking plate for the triplet is a great idea,my lens collects dust like anything,it will smooth the general look of the beast too!
I look foreward to seeing you tackle that one!!
Cheers P