INSTRUCTION SET #4

This forth instruction set is a combination of the 2nd and 3rd design. This design requires the same amount of work as the third, yet cost less than the third.

The materials you need to purchase for this projector design will cost you under $50, which puts it between the 2nd and 3rd design for cost. If you already have some of the materials, it will cost you that much less.

PARTS IDENTIFICATION

Below, there is a "Purchase List" for your convience for the store Menards.

TOOLS IDENTIFICATION

FASTENER IDENTIFICATION

When you purchase these fasteners, verify that they correlate with the slots within the plated angle pieces. The above fasteners should be close, if not correct. The washers are to prevent the bolts from falling out.

PURCHASE LIST

(The below is the list of parts for a 15" - 22" TV sized TV. If your TV is larger, you might need to purchase larger or a greater amount of various materials.)

Menards:

· 15" - 22" Television N/A

· 1/8 IN x 2 FT x 4 FT Hardboard (5 pcs) Lumber Section -mid-left side of bldg

· 1.25" x 1.25" x 4 FT Slotted Angle (5 pcs) Fastener Section - middle of bldg

· 1.25" x 1.25" x 3 FT Slotted Angle (1 pc) Fastener Section - middle of bldg

· Black Spray Paint (3 cans) Paint Section - back-right side of bldg

· Light Sand Paper (1 pckg) Paint Section - back-right side of bldg

· #10 -24 Stove Bolt 1/2" x 3/16" dia Flat (3 pks) Fastener Section - middle of building

· Zinc Plated 1/4" Fender Washer (5 pks) Fastener Section - middle of building

STEP #1

(Outer Box)

Cut the ply and angles to the above measurements. NOTE: The 1/8" is the thickness of the panel sheet.

STEP #2

(Panel Holes)

Drill three holes per side on each of the four ply sheets. The hole size is 3/16" or slightly larger.

STEP #3

(Outer Box)

First, fasten the Bottom Panel and its two corner pieces together using the bolts you bought. Do this same procedure with the Top Panel. Now, stand the assembled top and bottom and attach the side panels with bolts/nuts also.

STEP #4

(Inner Box)

Cut the panel and angles to the above measurements for the inner box also. Delta is the tolerance between the Inner and Outer Box. NOTE: The 19.25" = 20 - (the width of the inner length on the angles).

STEP #5

(Panel Holes)

Drill three holes per side on each of the four panels. The hole size is 3/16" or slightly larger.

STEP #6

(Inner Box)

First, glue Bottom Panel and its two corner pieces together. Next, staple the panels to the corner pieces for extra strength. Do this same procedure with the Top Panel. Now, stand the assembled top and bottom and attach the side panels with glue and staples also.

STEP #7

(Lens Panel & Inner Box)

Measurements shown above are the longest lengths on the angles. Cut the angles at a 45 degree angle. The 3/8" and the 1/4" figures on the angles are derived from adding ply (1/8) and angle thickness (1/8).

To find the center for cutting the 7 inch diameter hole, you must find the measurements above on your TV and then transfer them to the Lens panel.

STEP #8

(Fresnel Lens & Lens Panel)

Simply tape the 6x Fresnel Lens to the front of the Lens Panel with the ridged side facing toward you. When you have completed your projector, the ridged side should be facing the TV.

STEP #9

(Inner & Outer Box)

Inner Box is slid into the Outer Box and should fit not snug. The lens portion is on the inside, out of the line of sight.

STEP #10

(Completed Design)

Now, put the TV in the other end of the Outer Box. At this point, you will now have to use a wall or screen to project the image onto. You will probably need a table to set your TV and projector on, so you can move it into focus. Then, you need to do trial and error to find the right lens position (by sliding the Inner Box in the Outer Box) and find the right table position (the distance from the projector to the screen). Try larger distances between the projector and screen to produce a better larger picture. Note: Not all lens positions will focus when moving the table back and forth. So, you need to find the right combination between the two variable positions. In the near future, I will do some complex mathematical calculations using Optics and Engineering formulas to find the optimal position of the lens and projector. This will make it much easier for future customers to find the correct position.