I have been a member of the DIY PJ commmunity for a long time. Until now, I have not built any units.

I received my PRO REFLECTOR today!! Time to start the plog!

Since I first started watching this scene, I've always wanted to build a nice aluminum projector. I have finally committed myself. Parts have begun arriving and the workbench finally has room for a projector. I just have to try and finish before summer, because then the 5 motorcylces out in the garage become priority. LOL, I am a sucker for projects. Don't get me started on the list of restoration projects I'm working on, I'll never shut up.

So the parts I have so far:

LL s400DD light kit with eBallast
LL basic lens kit
LL pro reflector ( recieved today!! thanks LL, great piece of glass!! )

15 small small PSU units that provide 12VDC@2.5A+, and 5VDC for control voltages
(I bought a large quantity of these little power supplies because they are perfect for this hobby. Very small on an open frame. I like that because it gives me the freedom to build exactly the PSU I need with exactly the right connections in the right places. After I build a couple for myself, I'll simply offer the rest to anyone on the forum who wants them. This is something I always planned on doing for the DBG, but clearly things there didn't work out as expected. At least LL still rocks the house.)

I also have a bevvy of twelve volt fans in every shape and type conceivable, from pancakes to blowers to crossflow.

Over the past several months, I have been making alot of orders at AllElectronics, buying connectors and plugs and iec entry modules and switches of every type imagineable. It's safe to say that however I wire this thing, comlex or simple, I already have what I need to do so.

I haven't purchased an LCD yet, but I plan on leaving that till later. For now, since I have all the parts for the light box, that will be first.

My next post will outline some of my constantly changing ideas for this priojector.

One of the most important things to me in this project, is to use only alloy. I want no lumber anywhere on this unit. I intend to create a modular unit. The entire PJ will have an aluminum angle frame. The light box, the LCD/fresnel sammy, and the focus mech will all be easily removable from the unit, for modifications sake (I know I can't leave well enough alone and plan for it when possible lol) To avoid the problems of wavy sheet metal, I will instead skin the unit in thin Aluminium plate, which, with the eBallast, and all aluminum frame, should still make for a lightweight projector.

I also intend to fold the light path at least once, for the sake of size, perhaps twice. I plan to mount close to the cieling on a shelf, with enough keystone adj built in to also use it from a coffee table if necessary.

To me all these things mean semi-portability, which I want.

I could have went the timber route, but I really want to do something original, and I want to challenge myself. This will be a good exercise in learning to work with aluminum for me.

Now, as for cooling, I intend to use several high volume fans on a low enough voltage to make them inaudible. It's important to me to utilize the natural thermodynamics of the pj, not fight them, therefore all airflow in my PJ will go up, never down. This also allows the PJ to breathe with the room, not against it, as I see it. I want the light engine to be as high in the unit as possible, to avoid washing that hot air over any other equipment. I am hoping the new reflector will help greatly in this respect, so kudos to the LL team for having it made!

The electronics of my PJ will likely be complicated. And it's only likely to get more complex as I design it( since ideas come more easily than they go away). But for now, I know that the main power switch will operate a series of relays and latching relays that will turn everything on when on;and when switched off will shutdown the fans only after the temp has dropped sufficiently. I will have a motorized focus mechanism that will be controlled by a (on)off(on) spdt switch. I purchased several nice door lock actuators from AllElectronics that I am itching to find a use for as well. I've considered settin up the focus mechanism so that when the unit is turned off, it draws the lens all the way into the PJ, where the lens mech hits a momentary pushbutton, which sends a jolt of 12V to the actuator to close a lens flap or sliding cover. I've also considered that my airflow model may leave my unit susceptable to dust entering the unit from the air exit when off, so another actuated flap or door here might be a good idea. Time will tell. I have a sketch book full of different ideas I've been having about PJ electronics over the past couple years. That's enough for now.

So those are some of the basic ideas I have for my PJ.

Now that I've explained my PJ idea, let me lay out the steps I will be taking in the near future to get on that path.

1) Since I have all the parts for a lightbox except the alloy, that will be my first build. I need to go to the metal store and then I'll have all I need to build a sweet light box. I will build full three axis adjustment into the mogul mount, so I can compare the pulse strike and the s400DD later. I have a number of ideas about mounting the reflector, but which one I use will have to wait until I go to the metal store.

2)after I build the lightbox, I am going to make a fully adjustable test bed. I have seen some really nice aluminum channel with mating aluminum slides. I am going to buy some of this and make a fully adjustable test bed, that will be used for any projector I make in the future. It will allow me to independently adjust the distances between every piece of the optic puzzle with ease, and since I am going to build it with a long table saw style tape measure on both sides of the bed, I will be able to take notes without ever getting out the tape measure. This multifunctional test bed will likely be the only thing I ever use lumber for as far as my PJ builds go.

3)once the test bed is built, it's on to building fresnel frames, and designing a mounting sytem that can be used both with my test bed, and in the final unit

4)build the focus mechanism. I will also build a vertically adjustable platform for the test bed so that any focus mech can be mounted at the right height for any setup(on the test bed), including 15", 17", and 19" LCD setups.

5)design and test the electronics setup( as much as can be with no LCD)

6)select and buy an LCD

7)more to come.... after I do the first 5 steps, that is!