[basementjack]

I recently built a DIY 2.4:1 screen.....

50 inches tall, 120 wide (130 diagonal)

I don't have contruction pictures, but I'll outline what I did...

Frame: 5 boards total:
2x 1x4x12 foot 'select' from menards, $10 each
2x 1x4x6 foot 'quality' from menards, $2 each
1x 1x3x8 foot "select' from menards, $5
Wood total: $29

2 packages "L" brackets from wallmart $2 each
hardware total: $4

4.5 yards of black velvet from Joannes $12.99/yd, less 40% coupon
4 yards of blackout cloth from joannes $2.99/yd, less 10% coupon
Fabric total $46

Foam board: (to mask the 2.4 screen down to 1.78)
1 sheet pink 1/2 x 4x8 cut down to 2 panels of 50x15.5 $7.49
1 can spray adhesive $7
Masking total $15

Project total: $94

Construction:
Tools used:
Table saw
Miter saw
Router
hand Staple gun
Air staple gun
screwdriver
drill

I began by cutting 45 degree cuts on each end of the 4 1x4 boards - so that the inside dimensions were 120 on the longer 2 and 50 on the shorter two - I discarded the scraps.

That concluded the use of the miter saw.

Next I used the table saw, and cut the 1x3 down to 2 inches (a 1x3 is really .75 by 2.5 - so now its .75x2.0)
I then tilted the blade of the table saw to 30 degrees and cut the .75x2.0 piece lengthwise to make a french cleat to hang the screen.

That completed the cutting on the french cleat.

Lasly, I used the table saw to cut a few grooves on the back sides of the 1x4's -
I used these grooves for my staples, I'll try and provide a picture or drawing at some point in the future...

That concluded the use of the table saw...

I then used my router with a 1/4 inch rounding bit and rounded the edges of the 1x4s (only the audience facing edges, no the back sides)

That complted my use of the router.

Now I laid the black velvet face down on a setup table and put the board on top of the velvet.
I stapled the velvet to the boards on the backside, wraping around the front and stapled again on the back.

I then laid all 4 pieces on the floor in the theater room, face down.
I used the 'L' Brackets to screw them together.
measured both diagonals to ensure it was square.
installed the Blackout cloth - vinyl side down and stapled with the hand stapler (Hand staples are easier to remove than the air powered stapler.

Lastly I attached the french cleat to the frame, and to the wall.

Total project time - about a full day, including shopping.
Total project cost - $95 plus tax