Bryans Guide to Building a 100 Projection TV

Guide Revised: February 10, 2002 | Version 1.02

Background The goal here is to build a projection attachment that projects a standard TV or computer monitor signal onto a wall or screen thereby giving you a huge picture without paying thousands of dollars for a regular one. Dos Donts Do not pay for a similar guide on this subject. The best things in life are free! Do not open your TV (TVs can carry a charge, even after they are unplugged. Dont be stupid) Do feel free to donate if youve found this useful! We appreciate it! Do use mirrors to rotate the image so you dont have to rotate your TV Do have fun with the process. Do try to use a DVD player with the setup for focus calibrations. Make sure your lens's SMOOTH side is facing towards the SCREEN, the BUMPY side should be facing the TV!

Why do it? Because buying a projection screen TV is costly. This option offers a similar experience at a fraction of the cost. Why wouldnt you want to try it? Theres a display technology called OLED that should revolutionize big screen displays. Kodak is developing the technology. You can read more about it here. http://www.kodak.com/US/en/corp/display/overview.jhtml

Dont be THAT guy. Until that comes a long, this is a fun way to learn about Frensel lenses, do a little cut and tape project, and enjoy a ghetto 100 TV in the process.

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How Projection TVs Work Projection TVs form a small image on a device inside the projector -- either a CRT or LCD -- and then shine that image onto a large screen located elsewhere. In one type of projection TV, the screen is located within the TV box itself. This type of projection TV is called a rear or reflective projection; in this type, light reflects off the projection display panel and is then projected onto the screen.

Rear or reflective projection display system In another type of projection TV, the screen is located across the room. In this type of projection TV, called a front or transmissive projection, light passes through the image forming display panel and is then projected onto a screen.

Front or transmissive projection display systems

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Light from any point on an object spreads out in all directions. When the spreading light hits the page magnifier lens, it is bent toward the axis of the lens. (The page magnifier is called a positiv e, or converging, lens because it bends light rays together.)

Figure 1

Page magnifiers have a focal length of about 10 inches (25 cm). A focal length is the distance from the lens to an image the lens makes of a distant object. If an object is farther than one focal length (10 inches [25 cm]) from the lens, the lens can bend all the light that arrives from one point on the object until it comes back to a point on the other side of the lens. This point is a point on the image of the object. If you put white paper at the place where the light rays meet, an image will appear on the paper. An image that can be focused on a piece of paper is called a real image. (See Figure 1.)

Figure 2 If an object is closer to the lens than the focal point, the lens cannot bend the light spreading from the object enough to return it to a point. To your eye-brain system, it looks like there is an image on the

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same side of the lens as the object. This type of image is called a virtual image. It cannot be focused on a piece of paper. (See Figure 2.)

You can find the focal length of your particular lens using a bright light source that is more than 30 feet (9 m) away. CAUTION: Don't use the sun! The image you make can become so hot that it can burn the paper, and so bright that it can damage your eyes.) AKA, dont be an idiot! And, if youre ever a contestant on Survivor take a lens with you as a luxury item. The Frensel plastic lenses we use are made out of wedges of plastic. The wedges must be thicker at the edge in order to bend light more, and thinner in the center. Run your finger over the ridges of the Fresnel lens and notice that the ridges are higher near the edge and lower and smoother near the center.

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100" Projection TV Instructions These plans are very simple! Results will vary by types of materials you use and screen that is projected on. Works on TVs or monitors. Monitors and TVs under 19 will work better, be brighter, and deliver a picture thats more in focus. Materials These are the things you will need to make your 100" projection TV! A TV or computer monitor A flat surface to put your projector on. A Fresnel Lens Cardboard. Big pieces. Black Duct tape Compass pencil

Step1: Measure your screen (vertical and horizontal). The idea here is to make a light tight box around your TV. Doing so captures the light and channels it through the lens for a brighter picture. Measure the TV with a tape measure. Measure it vertically. Measure it horizontally. Now, youre going to use those dimensions to make a box that will be taped to the top and sides of the TV. Some might choose to use real wood, but its easier to use cardboard box pieces for these sides, but chances are youll have to do some cutting. The First Box Youll need to make 4 sides to this first box. The sides of the box will use your vertical measurements while the top and bottom will use your horizontal measurements.

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The Second Box Now youre going to need a second box. This will house the lens and slide into the second box so you can adjust the focus. Use the vertical, and horizontal measurements but decrease them by . This should make a snug, but adjustable fit into box 1. Once the four sides have been made use the black duct tape to put them together.

The Lens Now the lens. The last piece will be a circle that will fit the front of the box. Use the monitors height and the monitors width 1/2 to get your panel. Use a pencil to draw an X from corner to corner. Trace the biggest complete circle. Once you have done that use the measurement to recreate that circle in the center of the X you drew on the box. Cut out the circle. Now just line up the hole in cardboard with the biggest circle on the Fresnel lens, and tape it on. The lens should be on the inside smooth side facing in. Secure it with duct tape. Make sure the lens is on the inside of box 2 when you mount it to the front. Tape the lens panel on box 2.

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If youve followed plans correctly you should have a contraption that looks something like this:

At this point you should be ready to make a dry first run. Turn the lights out, turn on the TV and point it at whatever it is you are using for a screen. There should be a huge 100 blurry mess on your screen or wall. This is good. Slide Box 2 in and out of Box 1 to adjust the focus. If this works you should have a functioning projector on your wall. If the picture isnt bright enough dont worry, its probably your screen. See tips below! Inversion of image Most plans will tell you to turn your TV or monitor over. Kids, dont do this if your TV is 19 or more. If you do and your picture turns green theres a reason Normal TVs and computer monitors are not meant to be turned upside down. The only exceptions would be new flat screen LCD monitors. Heres the smart way to flip the image back around. Its possible to use 2 mirrors at 45 degree angles to flip the picture back around. Well be posting plans soon on how to add a third box to add these. Mirror Mirror on the wall - Front Surface Mirrors Everyone is familiar with going to the movies and seeing the image projected from the rear of the auditorium to the screen at the front of the room. Any type of projection system, whether film or video is the same: you create the image, magnify it, and project it through a lens to the screen. Unfortunately, even with custom tailored lenses, you end up with the "throw distance", or the distance from the projector to the screen being too long. Imagine trying to fit a rear projection television in your living room with a throw distance of ten feet! The cabinet would be huge, the cost would be enormous, and there would be no room for the couch and your coffee table! To get around this, engineers and optical designers use what is called a "folded optical system", that uses "short throw" special lenses in conjunction with mirrors to literally "fold" the optical path so that while the image's light path travels the same distance, the use of the mirror allows you to have a shorter cabinet depth by cutting the path in half.

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This type of design is what has led to the popularity of rear screen projection systems, but to make certain that light is not lost to internal reflections. Conventional mirrors, like the ones you probably have in your home are typically "rear surface" mirrors, meaning that the silvery material that gives the mirror its reflective properties is applied to the rear of the glass surface. This is great for checking to see if your hair is combed properly, or if your tie is on straight, but when light passes through the glass once, and is then reflected back out through the glass surface a second time, the light tends to scatter, resulting in the image losing focus. The mere fact that the image travels through the glass twice also results in a loss of brightness because the some of the light is absorbed during each pass. To eliminate these problems, projection televisions uses special front surface mirrors, made using a process that applies the reflective material to the front of the glass, rather than the rear. This way, the light image bounces directly off the mirrored surface without having to travel through the glass, thus avoiding losses and scattering. This assures a crisp, clear, bright image.

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Many projection TVs use glass, rather than coated Mylar film mirrors to assure a flat optical surface for perfect. Although front surface mirrors are more costly than conventional mirrors, and while they require specialized manufacturing and production equipment to protect the delicate reflective surface, they are a key element in contributing to the exquisite performance of projection TVs. Recommended Screen Materials Although the light coming out of a projection box will be magnified, the lens will still not carry all of the light. What you use as a screen will help determine factors like picture brightness and clarity. In this section we will focus on different screens pros and cons. Types of heavy white vinyl Matte white: 5% reflectivity, black is very dark gray to black and the image is not very bright Pearlescent: 15% reflectivity, black is dark gray and image is bright, provides best overall contrast. This kind is found in most movie theatres. Silver: 30% reflectivity, black is medium gray and image is very bright, dark colors can seem a little dull Glass bead: 40% or more reflectivity, black is light gray and image is usually too bright, normally used only under special circumstances. Distance from Wall 5 Feet 6 Feet 7 Feet 8 Feet Screen Size 50" 70" 80" 100" Picture Quality Superior Excellent Above Average Very Good

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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 havent 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 youre using, not the projector itself. Its been said that Testor's Enamel in Metallic Silver or Krylon Bright Silver Enamel makes a good screen if you coat your plywood or desired surface with this.

Bryans Ghetto Projection Project Version 1.0

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On a 19 screen I had a massive image on the wall. It was blurry on the edges, but you could immediately see the potential! Im planning to get a smaller Monitor and perfect this. Where to get your Fresnel lens 1. 2. 3. http://www.apollopresentations.com/ProductPages/MagnifiersDetail.asp?data=Full+Page +Magnifier Office Depot (Apollo Full Page Magnifier, 8 1/2" x 11" $8.29) Staples (Full Page Handheld Magnifier, 8 1/2" x 11" $7.59)

Donations If you feel like this information has done you some good please pass it to others! People are making money from this idea, and its crazy. What were doing with this no different then what TV makers were doing with projection TVs in the late 40s! If you feel like you want to make a donation please do. You not only keep this information free, but support OriginalPlots.com. Just head to http://www.originalplots.com/100inch.html to donate, or learn about updates to this guide. Disclaimer Im not responsible for any equipment damage you may have as a result of misusing this information. If you follow the directions carefully, you shouldnt have any questions or problems. Ive done my best to include pictures of everything! This document is meant strictly as an entertainment resource. I cant make any guarantees or promises on how well it will work. This guide is meant to be used free of charge. If you charge anyone for this youre a loser. If you paid for this guide blame the guy who sold it to you. Also, keep in mind that this guide is always being updated so check back for the latest! Spread the word kids. Have fun! Bryan ONeill bryan@originalplots.com February 2002

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