Tom's DIY Laminate Screen Project

We received an email from Tom telling us about his DIY Laminate Screen Project and thought it would be a good thing to share with you all:

I completed my dedicated basement home theatre last December and I built a WilsonArt Designer White (matte finish) laminate screen.  I must say that I couldn't be happier!  I won't belabor all of the details, since I stole the ideas from AVSforum and Home Theatre Shack online.  I'm guessing I had $250 worth of materials in the screen, counting the laminate, poplar frame boards, pocket hole screws, z-bar hangers, trim boards, and velvet.  I now have a 120" (2.35:1) and 96" (16x9) beauty, and absolutely love the results!

WilsonArt designer white in matte finish. Purchased 4' x 10' sheet. Didn't need that entire length.

1" x 4" poplar boards, joined together with pocket screws.

Frame only with a test hang on the wall using four zbar hangers. Put them at top and bottom of each side to keep the frame flat against the wall. zbar is great as it allows some side-to-side adjustment to get final screen mounted in the center of the wall.

The laminate has been cut (straight edge and utility knife) and mounted to the poplar frame. Note the 5/8" drywall screens around the perimeter to hold it to the frame. Pre drill pilot holes through laminate to prevent breaking.

Wrapped pre-primed trim boards with black velvet (45 degree angles on each end). Velvet stapled on the back of the trim boards, and trim boards attached to the frame from behind with 1" drywall screws. Note velvet frame covers drywall screws used to mount the screen. Final size is 96" for 16x9 and 120" for 2.35:1.