Construction: Steps 5-8

Creating the lens mount and painting the interior

Step 5: The Focusing Board

Now we will cut the "focusing board." This panel matches your screen's height and width and will serve as the front face for an internal box that slides snugly into the outer enclosure.

Focusing board diagram

Step 6: Centering and Cutting the Lens Hole

On your focusing board, draw a large "X" by connecting opposite corners with a straight line. This find the exact center. Place your Fresnel lens over the center, trace its circular outline, and cut out the hole.

Centering lens Marking circle
Important: The lens must fit precisely into this hole. If using cardboard, you can angle your blade to create a "beveled" cut so the back of the hole is slightly larger than the front.
Beveled cut diagram

Step 7: The Inner Box & Painting

Create the inner box following the same logic as Step 2, but make it 9 inches deep and slightly smaller in girth so it can slide inside the main enclosure. Now, paint the interior of all panels matte black. This is critical for preventing light bleed and ensuring a clear projection.

Painting panels black

Step 8: Assembly

Once the paint is completely dry, use duct tape to assemble the panels into their box shapes. Ensure the black-painted sides are on the inside. You should end up with two separate box structures: the main enclosure and the smaller inner focusing box.

Taping boxes
Next: Steps 9-12