DIY Projector Screen with Painted Wall and Wood Frame
Step-by-step guide made from Our Home In Making's YouTube video.
This project demonstrates how to create a high-quality home theater projector screen by mixing custom paint and applying it directly to a wall. It also covers building and installing a simple, clean wooden frame to complete the theater look.
- Difficulty: intermediate
Safety
- Always wear safety glasses when operating a miter saw or using a hammer and chisel.
- Ensure power tools are unplugged before making adjustments or changing blades.
- Use adequate ventilation when painting indoors.
Must know before you build
- Mix specific Behr paints: 1/2 gal #1050, 1/4 qt #1300, 1 sample #5400 for screen.
- Paint 1x4 frame boards *before* cutting and nailing to simplify finishing.
- Notch frame for outlets using a hand saw and chisel for a flush fit.
- Use a miter saw for precise 45-degree frame cuts; crucial for tight corners.
- Apply wood glue to mitered frame corners *before* nailing for lasting strength.
- Surround screen with lime wash paint for a distinct, textured wall finish.
Tools
- Paint roller
- Miter saw
- Hand saw (optional)
- Chisel (optional)
- Hammer (optional)
- Nail gun (Brad nailer)
- Drill/Driver (Cordless drill/driver)
- Level
Materials
- Silver Screen Paint (1/2 Gallon, Flat, Matte, Behr, #1050)
- Black Matte Paint (1/4 Quart, Matte, Behr, #1300)
- Dark Pewter Paint (1 sample bottle, Semi-Gloss, Behr, #5400)
- Lime wash paint
- 1x4 lumber
- Wood glue
- Wood filler
- Black paint
- Painter's tape
Step by step
Step 1: Mix the DIY Screen Paint
Combine the three specified paints in a bucket to create the custom screen paint.
- Combine the Paints. Pour the three different paints—Silver Screen, Black Matte, and Dark Pewter—into a large mixing bucket.
- Review the Formula. Confirm the specific paint names, colors, finishes, and quantities needed for the DIY screen paint.
- Tip: The formula is: 1/2 Gallon Silver Screen (Flat, Matte, #1050), 1/4 Quart Black Matte (#1300), and 1 small sample bottle of Dark Pewter (Semi-Gloss, #5400).
Step 2: Apply Screen Paint
Although the painting isn't shown, the creator applied three coats of the mixed screen paint to the taped-off area on the wall, then removed the tape.
- Remove Painter's Tape. After applying three coats of paint and letting it dry, carefully peel away the painter's tape to reveal the crisp edges of your new screen.
- Tip: Apply three coats of the screen paint to get a smooth, even finish without any roller marks showing through.
- Common mistake: Applying the paint too thickly or with an improper roller can leave visible marks and texture on the screen surface.
Step 3: Paint the Surrounding Wall
Protect the new screen area and apply lime wash paint to the surrounding wall to create a dark, non-reflective border.
- Protect the Screen. Cover the newly painted screen area with plastic sheeting and secure it with painter's tape to protect it from the new wall paint.
- Apply Lime Wash. Using a brush, apply the lime wash paint to the wall surrounding the screen area. The creator uses a dark color to match the other walls in the media room.
Step 4: Measure and Cut the Frame
Use the projector to mark the exact dimensions for the 1x4 frame, then cut the corners at a 45-degree angle with a miter saw.
- Mark Frame Dimensions. Turn on the projector to display the screen's boundaries. Hold a 1x4 board up to the wall and mark the exact cutting points to frame the projected image perfectly.
- Cut Mitered Corners. Set your miter saw to 45 degrees and cut the ends of each 1x4 board at your marks. This will create the mitered corners for the frame.
Step 5: Notch the Frame for an Outlet
To accommodate an existing electrical outlet, use a hand saw and chisel to cut a notch in the back of the bottom frame piece.
- Mark the Notch. Identify where the electrical outlet cover interferes with the frame. Measure and mark the area on the back of the 1x4 board that needs to be removed.
- Cut the Notch Edges. Use a hand saw to make several parallel cuts into the back of the board, down to the depth of the notch you marked. Do not cut all the way through the board.
- Chisel Out the Wood. Place a chisel at the base of your saw cuts and tap it with a hammer to break away the small pieces of wood. Continue until you have a clean, flat notch.
Step 6: Install the Frame
Attach the 1x4 frame pieces to the wall around the screen using a nail gun and screws, applying wood glue at the corners for strength.
- Attach the Boards. Position the frame pieces one by one around the screen area, using a level to ensure they are straight. Secure them to the wall using a nail gun, and add screws where you can hit a wall stud for extra support.
- Glue the Corners. For a tight and durable joint, apply a bead of wood glue to the mitered edges of the corners before nailing the final pieces in place.
Step 7: Paint the Frame
Fill any nail holes with wood filler, sand smooth, mask off the screen, and then paint the entire frame black.