DIY Wall Mount Projector Projection Screen

Earlier this year I bought a new projector and needed a screen for it.  I knew the length of my TV stand was 96" and I wanted my frame to be a tiny bit wider than that so using the 16:9 aspect ratio I knew my height would be 54", by using the Pythagorean theorem I would have an approximately 110" screen (before adding the border).  I found blackout cloth that was the right size and ordered it.


Materials:
1x 66"x110" projector screen material 
1x roll of felt for the border
1x 1x6 (it was what I had in the garage) which I ripped in to pieces.


I started out by building the frame, a simple square.  I attached the corners and middle "stile" using a Kreg pocket hole kit.

In order to mount the frame to the wall and keep it snug I:
1) Using a router and a 3/8" rabbet bit and cut a lip on the front side of the top of the mount.
2) Because I didn't want a visible cleat on the bottom and I wanted the screen to be snug against the wall I attached a cleat near the bottom corners using pocket screws
3) To hold the top against the wall I cut and attached two long cleats to the wall, routing a matching rabbet, this time on the wall side of the cleat.  This makes sure it's nice and snug to the wall all the way across the top.
4) Then I cut two small cleats to put at the bottom of the screen, keeping the whole thing snug against the wall.

I test fit everything like this to make sure I was happy with the set up.

Once I had my dry-fit done it was time to stretch the material.  I don't remember whose process I followed but the gist of it was to start from the middle and work your way out, keeping tension on the screen with each staple like explained on this page.  It took me about an hour to work my way around.

Once I had the material stretched I cut the felt to length and stuck it to the screen, and hung it. 

Since I love Top Gun I always use it to test audio / video upgrades.  Here's the final product.  We've been using it for 6 months now and haven't had any issues.  Today I took it down and hung a 60 mile OTA antenna behind it  (you might notice the black cord coming out the bottom right corner of the screen).  I'll hit the exposed piece of cord with some house paint in a few weeks and it will blend right in. 

Tada: