INSTRUCTION SET #2

This second instruction set is the standard design using wood for material. This design requires more work than the first, but it is also higher quality. If you want make your projector in the standard format without spending much more money, this is the instruction set for you.

If you have purchased other TV projection designs from eBay sellers, you will notice quickly that these four instruction sets are higher quality than at least 3 of the 4 designs in other plans. We actually use bolts, staples, and glue to put our projectors together. Most other plans use tape. It is true, duct tape can fix about anything, but we believe that our customers would probably prefer a little higher quality in their projector.

PARTS IDENTIFICATION

On this page, there are two "Purchase Lists" for your convience, one for Menards and one for Home Depot.

TOOLS IDENTIFICATION

PURCHASE LIST

(The below is the list of parts for a 15" - 22" TV sized TV. If your TV is larger, you might need to purchase large sized wood pieces.)

Menards:

· 15" - 22" Television N/A

· 1/8 IN x 2 FT x 4 FT Hardboard (5 pcs) Lumber Section -mid-left side of bldg

· 1 IN x 1 IN x 8 FT Solid Pine Corner (3 pcs) Trim Section - back-left side of bldg

· Black Spray Paint (3 cans) Paint Section - back-right side of bldg

· Light Sand Paper (1 pckg) Paint Section - back-right side of bldg

· Wood Glue (1 bottle) Hardware Section -3rd row front bldg

· Staples 7/16 Heavy Fastener Section - middle of building

Home Depot:

· 15" - 22" Television N/A

· 1/8 IN x 2 FT x 4 FT board (5 pcs) Plywood Lane - reg #1, right side bldg

· 1 IN x 1 IN x 8 FT Solid Pine Corner (3 pcs) Plywood Lane - reg #1, right side bldg

· Black Spray Paint (3 cans) Paint Section - left side of bldg

· Light Sand Paper (1 pckg) Near Paint Section -reg #9, Door Sect

· Wood Glue (1 bottle) Near Paint Section - reg #9

· Staples 7/16 Heavy Fastener Section

STEP #1

(Outer Box)

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

(Inner Box)

Cut the ply and corners to the above measurements for the inner box also. Delta is the tolerance between the Inner and Outer Box. In other words, Delta is the margin of error. NOTE: The 19.25" = 20 - (the width of the inner length on the corner pieces).

STEP #4

(Inner 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 #5

(Lens Panel)

All measurements shown above are total (longest) lengths. Cut angles on corners are 45 degree. The 7/8" and the 1/2" figures on corner pieces are derived from adding panel (1/8) and corner thickness (3/8).

To find the center for cutting the 7 inch diameter hole, you must find the measurements above on your TV and then transfer them to the Lens panel.

STEP #6

(Inner Box & Lens Panel)

Assemble the Lens Panel Trim onto the Inner Box using wood glue and staples. Staple the paneling to the trim and not vice-versa.

STEP #7

(Fresnel Lens & Lens Panel)

Simply tape the 6x 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 #8

(Inner & Outer Box)

Inner Box is slid into the Outer Box and should fit partially snug with the lens portion on the inside, out of sight. The 2" corner pieces add needed strength to the Outer Box corners to avoid cracking from pressure.

STEP #9

(Completed Design)

Now, put the TV in the other end of the Outer Box. At this point, you will now have to use a wall or screen to project the image onto. You will 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 Inner Box 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 back and forth. So, you need to find the right combination between the two variable positions. In the near future, I will do some complex mathematical calculations using Optics and Engineering formulas to find the optimal position of the lens and projector. This will make it much easier for future customers to find the correct position.