DIY Projection Screen Frame
Blackout Frame Fabric Application Instructions
A guide to creating a virtually seamless and professionally cover projection screen frame.
For our instruction here we are using a both a mocked up small scale DIY projection screen frame and an actual size frame with our AVFF-02 blackout Framing Fabric with adhesive backing. The same principles and techniques employed here can certainly be used on large format frames as well as frames of different shapes or different frame covering materials. The cost of framing fabric for our 110" DIY Projection Screen Frame is app. $36. Level of Difficulty 5 out of 10.
Ruler or Straight Edge
Adhesive Backed Frame Fabric AVFF-02
Sized for 110" Diag.
100" x 106" - Qty: 2
10" x 64" - Qty: 2
Note: The adhesive backed frame fabric is sold at 54" roll width x linear yard (36")
You will have to mark the back and cut to appropriate size.
Step 2 - Application of Frame Fabric Instructions
1) We recommend ordering enough width of material to wrap the frame to the inside edges and 2" longer than the final frame dimensions. This way, trimming the fabric is easier. If you are using our DIY 15 Deg Frame design you will need 10" of width in material.
2) The frame should be completely assembled without the projection screen material mounted prior to continuing.
3) The frame should be lightly sanded with 220 or finer grit sandpaper and wiped with a tack cloth or solvent prior to applying the framing fabric to ensure maximum adhesion of the material. Priming and or painting the frame will also assist with adhesion but is not necessary if you have a nice smooth and clean surface. Painting the frame black or the same color of the fabric will also assist with the oops factor where things might go wrong with the fabric application thus preventing the appearance of bare wood.
4) Work should be performed in a large flat clean area.
5) We typically ship the Framing Fabric rolled so you may want to lay it out flat for a little while to make it easier to work with.
6) Lay the framing fabric along the edge of the frame. Do the short sides first. this way you can establish a technique for when you get to the longer more difficult sides.
7) Remove the protective paper from the back of the framing fabric to expose the adhesive side up.
8) Using spacers raise the side to be covered. Measure 1.75" of material to be placed under the frame from the bottom outside edge if you are using our DIY 15 DEG Projection screen frame design and have 10" width of framing fabric.
9) Remove one spacer and let the frame corner rest on the framing fabric adhesive side.
10) Go to the other corner and pull on the framing fabric to remove any ripples in the fabric. Hold the framing fabric in position, remove the other spacer block and let the second corner down on the framing fabric.
11) Because the sides are long it is difficult to wrap the fabric up the edge. To help get us started we actually pick up the opposite edge of the frame and slowly roll the frame so it side edge of the frame side to be covered is sitting on the fabric. This way it is applied in one smooth easy uniform action free of wrinkles and bubbles. Then let the frame back down. The material should now be adhered to the side edge as shown below.
12) Slowly crease the material up so that it folds and lays onto the top surface. This should be done by running you finger successively along the entire edge of the frame so that the material flaps over on its own. You do not want to do this is one motion. This took about 3 rubs along the edge before it laid down for us. Once it lays down you will need to slowly work the material from the top edge to the bottom edge so that there are no bubbles or wrinkles. We actually grabbed the edge of the material, pulling it taught while working the material down. Again work the whole edge. If you start at one end and rub the material down completely and then move down the frame you will likely end up with wrinkles.
13) Using a sharp razor trim the inside corner by running the razor along the inside edge of the frame sides without fabric.
14) Fold the center inside section down and wrap under the frame. It helps to have the frame raised off the floor with spacer blocks. Now the inside edge is trimmed and finished.
15) Important Step. Using a ruler or straight edge cut app. 1/8" outside the corner crease and remove excess material (Both Corners).
16) Flip the frame over to expose the bottom fabric for trimming. Before trimming you may need to pull back the fabric to get the material tight along the side and bottom corner.
17) Cut along the inside edge of the unfinished side to allow the frame fabric to be folded down.
18) Fold down the fabric, rubbing as you go to ensure good adhesion and to remove air bubbles.
19) Trim the outside edge along the unfinished side to remove the excess material with a sharp razor blade. You can work from top to bottom or vise versa.
20) Trim the bottom edge corner to remove excess fabric. Not critical as this will be an unseen edge but you can use the same 1/8" overlap procedure we used on the top to create a seamless edge here as well.
21) This side is now done and should look something like this.
22) Put the blackout framing fabric on the opposite side exactly as you did the first side above.
23) Perform steps 6 thru 20 for one of the perpendicular sides.
24) Important Step: Using a sharp razor trim the inside corner by running the razor along the inside edge of the frame. Note: The edge you are sliding the razor on has finished fabric on it. Be very careful to keep the razor flat along the edge or you will cut your finished fabric. Do both sides.
25) Fold the center inside section down and wrap under the frame. Now the inside edge is trimmed and finished.
26) Important Step. Using a ruler or straight edge cut down the center of the corner crease and remove excess material (Both Corners). If you used the AVFF01 fabric we offer you should not have a pretty seamless edge. The AVFF01 Framing Fabric is black with a black substrate so it should look pretty clean.
27) Trim the excess outside edge material from top to bottom. Note: The edge you are sliding the razor on has finished fabric on it. Be very careful to keep the razor flat along the edge or you will cut your finished fabric. Do both sides.
28) Flip your frame over and trim the inside corner so the material can be folded down inside the bottom of the frame.
29) Cut your bottom corners and remove the excess material. Again this is not critical as this will not be seen. We tend to be on the picky side so we're using a straight edge again.
30) You've now finished the third side and things should be looking pretty good.
31) Repeat steps 6 thru 29 for your last remaining side.
32) Congrats you are done with putting Fabric on your DIY Projection Screen Frame. It should look something like this. No staples are required to hold the material in place.
Next - Step 3: Attach Frame Mounting Rail
Jump to Step 4: Attach Projection Screen Material
Jump to Step 5: Mount the DIY Projection Screen to the Wall
Go Back to Step 1: DIY Projection Screen Frame Fabrication Instructions
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