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I decided to redo my frame which I had originally done with pvc pipe. It served its purpose but I wanted a tighter cleaner look so I made this frame out of emt. I think it turned out well but in hindsight I would have used 1” emt instead of the 3/4”. I had some sag at the top but not too bad and should last a long time. I pretty much duplicated my pvc build which was to wrap my screen around the frame ang bungee it. I was able to get my screen much tighter with the emt frame. I always struggled to get good tension with the pvc frame and could never get all the wrinkles out. I have the Carl’s standard screen which is about 3 years old or so. It doesn’t produce to best picture and allows a lot of bleed through. I used blackout curtains directly behind my screen and this does a great job with the bleed through. I was able to just slide the curtains right on the top bar and safety pinned them together. I then have netting behind that
My biggest issue, same issue I had with pvc screen, was protecting the emt pipe from bounce back. Since I wrap my screen around the pipe, I struggled with a way to attach foam to the screen without making some holes in the screen. I tried industrial Velcro on my pvc screen but it just didn’t hold well. Thanks to the help from DirtyGarry24, I was able to come up with a solution. I ended up attaching foam to plywood then wrapping with blackout cloth. I then built a wood frame on the sides of the emt frame and secured the wood to the emt with hose clamps. I then attached the foam to the wood frame with screws. I did this for both sides. On the top and bottom I was able to just use the foam backed with ply wood and attached sheet metal that I bent over. On the bottom I just had to slide under the screen. On the top I had to secure with bunnies. All in all I think it worked well. It is very very time consuming and a PITA but I think it was worth the effort. Someone with better skills at cutting and wrapping the foam would probably make it look much better but I found out I am quite bad at doing that but it still looks ok.
My biggest issue, same issue I had with pvc screen, was protecting the emt pipe from bounce back. Since I wrap my screen around the pipe, I struggled with a way to attach foam to the screen without making some holes in the screen. I tried industrial Velcro on my pvc screen but it just didn’t hold well. Thanks to the help from DirtyGarry24, I was able to come up with a solution. I ended up attaching foam to plywood then wrapping with blackout cloth. I then built a wood frame on the sides of the emt frame and secured the wood to the emt with hose clamps. I then attached the foam to the wood frame with screws. I did this for both sides. On the top and bottom I was able to just use the foam backed with ply wood and attached sheet metal that I bent over. On the bottom I just had to slide under the screen. On the top I had to secure with bunnies. All in all I think it worked well. It is very very time consuming and a PITA but I think it was worth the effort. Someone with better skills at cutting and wrapping the foam would probably make it look much better but I found out I am quite bad at doing that but it still looks ok.
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