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· Moderator Emeritus
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I too would recommend a one-piece screen if at all possible. Look for a large sign manufacturer in your area and tell them your needs; they should either be able to sell you the plastic sheet themselves or at least point you to their supplier.

While I think I would prefer a thick piece of plastic (1/4" or so) so it would be self-supporting, it should also be possible to get a thin sheet and glue that to your composite hardboard screen. One of the problems with composite screens is that the filler material can absorb paint differently than the hardboard and you get a discernible difference in the painted finish. Even a thin plastic sheet would prevent that.

A member here made his screen out of vinyl flooring on a wooden frame and he was quite happy with it. http://www.hometheatershack.com/for...ens/16799-mega-screen-black-widow-flavor.html
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