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Zangmonkey
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Building a projector hushbox

This is a duplicate of a thread I just posted at [H]

Recently my church acquired a small Epson powerlite projector. It works fine for our needs the only problem is the noise (worse because we have to run it in high-altitude mode).

I wanted to build a hushbox for it so not only to silence it but to keep the projector in a box where people wouldn't stress the wires, inadequately cool it or be confused by whatever else.

This is my hushbox build.

The plan is to add intake and exhaust fans with filters, which will move air through baffles and the projector.
The projector will be in a center cavity which at least one air gap between itself and the outside on all sides (except top and bottom, but I have used thicker MDF sections along with felt and foam for this.

Materials
3/4 MDF (Home Depot)
Black craft felt (Wal Mart)
Assorted craft foam (Wal Mart)
Spray on adhesive
Wood glue
Power strip
VGA cable
HDMI cable
1.5 inch torx screws (Home Depot)
2x single-gang low-voltage drywall mount boxes (Home Depot)
VGA Wallplate
HDMI Wallplate
Wireless IR extender
2x 4.5 inch anti-reflection glass windows
3x 120mm Fan Filter and Grill
2x 4-pack 120mm fans (used 6 only)
Molex adapter
multi-fan adapter


Started by cutting all the MDF into sizes I thought I wanted to use


Plug in all the fans, make sure they run!


This is my general drawing of how I want to lay it out:


Measure from the bottom where the screws will go for the sides, then glue and screw!:


Of course, clamp all glued surfaces... I wanted the outer sides to be fully dry before doing anything internally so this was the last for this day:



Lack of foresight!! I didn't check to make sure the throw of the projector would be ok through the MDF (didn't account for the thickness!) so I drilled the hold and test... everything was good.
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Old 11-30-2010, 06:43 PM Zangmonkey is offline  
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Zangmonkey
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This is the general layout, nothing glued, just setting things up so I make sure everything fits like I think it should:


Slight oversight again... I need to make the lens baffle removable so that I can clean the glass if needed... here I am gluing in some guides.


MDF sides are dusty and suck up paint, so I "painted" them with a mixture of woodglue and water to "seal" them... dry them with a heatgun because I am impatient:


Tada, front and rear removable sliding baffles!



Now just double check to make sure I'm not clipping on the minimum throw for this lens.... good:



Drill holes in both sides for the fans:


Then test fit them:

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Zangmonkey
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also cut out rectangles for the source boxes, then prime it


then paint it (this is just some dark color that was in the discount mis-tint bin at home depot. I had the guy add a bunch of black so it


I didn't think ahead of how to mount the glass.... I decided I would make strips of felt then pinch the glass in place... this way the glass is removable:


add little feet to it:


then begin the annoying process of gluing felt to all surfaces:
Next time, glue to all flat surfaces then cut as needed when you want to put it together....




Mount the surface boxes and faceplates and fans





Because there are no baffles on the top or bottom, I am lining it with foam, then felt:

blurry pic of felt overtop of foam:



The projector will sit on a pedestal inside the box which has foam where the projector will sit for grip, and felt on the bottom (for grip against the felt lining). This should provide enough vibration and sound dampening:



Here it is with the pedestal inside and mostly lined in felt:


I didn't like seeing the brown MDF through the outer window, so I painted the insert black:



To top of the box is lined with foam, then felt:




The projector sits inside of the box. On top of the projector, I have an MDF block covered in felt and foam.... this will gently pinch the projector in place and I can position is to open or restrict the air passage from the fans.
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Old 11-30-2010, 06:44 PM Zangmonkey is offline  
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Zangmonkey
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I will finish and test it all tomorrow and take pictures of the block so you can see what I'm talking about.
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Old 11-30-2010, 06:45 PM Zangmonkey is offline  
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+1 to DIY
Old 11-30-2010, 07:05 PM afxacid is offline  
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jayjaya29
 
Will the remote control still work for the projector?
Old 12-01-2010, 08:43 AM jayjaya29 is offline  
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asa
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you're going to use felt for sound dampening?

i would think that would get hot
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Old 12-01-2010, 09:18 AM asa is offline  
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Zangmonkey
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Quote:
Originally Posted by jayjaya29 View Post
Will the remote control still work for the projector?

I have an RF remote extender inside the rear baffle.
Then I can place the RF eye anywhere in the room.
Because the original remote is IR, I need to do this anyway for the high ceiling mount which is ultimately intended.
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Zangmonkey
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Quote:
Originally Posted by asa View Post
you're going to use felt for sound dampening?

i would think that would get hot

I went with felt because it was cheap.
I can easily strip it out if it doesn't work well enough... really the MDF does most of the dampening of the hum from the projector... the felt absorbs echos and vibrations.

As for heat, this box should have over 100cfm of total airflow.
I think that will be enough to cool it but thats why I still need to test it.
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Old 12-01-2010, 09:45 AM Zangmonkey is offline  
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Lurker
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What are you guys doing that you need a dead silent projector?
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Old 12-01-2010, 10:07 AM Lurker is offline  
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Zangmonkey
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Quote:
Originally Posted by Lurker View Post
What are you guys doing that you need a dead silent projector?

The projector is noisy, plus it's more likely to get damaged, full of dust, or worn out if it isn't enclosed and stabilized.

As far as silence goes... it's nice to not have loud whirring noises during prayers, meditations, films, etc....
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Old 12-01-2010, 10:29 AM Zangmonkey is offline  
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what do the onlookers think? will this be overkill?

Quote:
Originally Posted by Zangmonkey View Post
it's more likely to get damaged, full of dust, or worn out if it isn't enclosed and stabilized.
and it's less attractive of a nuisance for even well meaning technotards to accidentally tinker with it

Quote:
Originally Posted by Zangmonkey View Post
As far as silence goes... it's nice to not have loud whirring noises during prayers, meditations, films, etc....

out of curiosity- what variety of religion?
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Old 12-01-2010, 04:21 PM RedEyes is offline  
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chuckybob
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i normally think AV stuff is a waste of time, but this is cool
Old 12-01-2010, 08:02 PM chuckybob is offline  
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odd
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I guess your god isn't so great if he cannot hear you beg over the sound of a projector.
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Old 12-05-2010, 01:59 AM odd is offline  
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Zangmonkey
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Quote:
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I guess your god isn't so great if he cannot hear you beg over the sound of a projector.

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