REGULAR TV / MONITOR CONSTRUCTIONS - Design 1

| Design #1 | Design #2 | Additional Info |  

The first instruction set is the simplest of all others. The upside to this design is that it does not require much work, allowing you to finish it quicker. If you want to just try it out and don't care about the quality of the design, this is the instruction set for you. This will also work well for those who aren't craftsman-inclined.

Required Parts:

  • 15" - 22" Television or monitor
  • 1/8 IN x 2 FT x4 FT Hardboard (4 pcs) or 1/8 IN x 2FT x 4 FT (1 pc) & 1 pc @ 8FT
  • 1 IN x 1 IN x 8 FT Solid Pine Corner (2 pcs)
  • Black Spray Paint (3 cans)
  • Wood Glue (1 bottle)
  • Staples 7/16 Heavy

  STEP 1 (Outer Box)

 

  - Height of each one corner is 27.5".

  - Left (Right) Side: W = TV Height + 1.8", H = 27.5"

  - Top (Bottom) Side: W = TV Width +1.8", H = 27.5"

Cut the ply and corners to the above measurements.

NOTE: the 1/8" is the thickness of the ply sheets.

 

STEP 2 (Outer Box)

First, glue Bottom Panel and its two corner pieces together. Next, staple the panels to the corner pieces for extra strength. Do this same procedure with the Top Panel. Now, stand the assembled top and bottom and attach the side panels with glue and staples also.

STEP 3 (Lens Panel)

All measurements shown above are total lengths. Delta is the tolerance between the Lens Panel and the Outer Box. The tolerance is create a snug fit between the Lens Panel and the Outer Box.

 - Two corner pieces: H = TV width - Delta

 

 - t.w. -  Left edge of TV screen to right side of TV;

 - b.h. -  Top edge of TV screen to bottom side of TV;

 - b.w. - Left side of TV to right edge of TV screen;

 - t.h.  - Bottom edge of TV screen to top side of TV;

 

To find the center for cutting the 7" diameter hole, you should find the measurements above on your TV and then transfer them to the Lens Panel.

STEP 4 (Fresnel Lens & Lens Panel)

Simply tape a Fresnel lens to the front of the Lens Panel with the ridged side facing toward you. When you have completed your projector, the ridged side should be facing the TV.

STEP 4 (Fresnel Lens & Lens Panel)

Assemble the Lens Panel Trim (2 horizontal pieces) onto the Lens Panel using wood glue and staples. Staple the paneling to the trim and not vice-versa.

The Lens Panel is positioned within Outer Box and should fit snug. The 2" corner pieces add needed strength to the Outer Box corners to avoid cracking from pressure or movement.

STEP 5 (Complete Design)

Now, put the TV in the other end of the Outer Box. At this point, you'll now have to use a wall or screen to project the image onto. You'll probably need a table to set your TV and projector on, so you can move it into focus. Then, you need to do trial and error to find the right lens position (by sliding the Lens Panel in the Outer Box) and find the right table position (the distance from the projector to the screen). Try larger distances between the projector and screen to produce a better larger picture.

NOTE: Not all lens positions will focus when moving the table and forth. So, you need to find the right combinations between the two variable positions.

Troubleshooting

Before using the projector, check the tuning controls first. Only when your TV picture is bright and sharp will your enlarged image also be the same.

Remember these are images greatly enlarged anywhere from a single foot to an amazing eight-foot widescreen image! This will inevitably reduce the brightness and sharpness of the picture somewhat.

How can I fix a blurry picture?

Make sure your TV is adjusted correctly. The projector may need focusing. Make sure the smooth edge it toward the TV, and the grooved edge is away from it. Clean the lens with Windex, or water.

How can I fix a dim picture?

If your box is light tight, your projection should be decent enough to view. Even if you haven’t painted your boxes enough light should come out. If you do paint your boxes, remember – black absorbs light.

Painting the inside of your box black is probably not a good idea. If you need to brighten up the picture, just worry about the screen you’re using, not the projector itself. It’s been said that Tester’s Enamel in Metallic Silver or Krylon Bright Silver Enamel makes a good screen if you coat your plywood or desired surface with this.