Determine the desired size of your finished screen first. Here, we used standard 8' lengths of furring strips for the long sides: the top and bottom of the frame and cut two pieces of 6' furring strip for the sides using a Saw-Max fitted with a SM500 Wood and Plastic Blade.
Secure all pieces of your frame together by joining the sides using thin wood screws. Use your Dremel Rotary Tool and a 150 1/8" Drill Bit to drill pilot holes before screwing together so as not to splinter the wood. Tip: When drilling pilot holes using your Dremel Rotary tool, set your tool to a higher speed for harder materials and at a lower speed for softer materials. For this project we are using pine furring strip which is a softer material. Set your Variable Speed Dremel Rotary Tool to 15,000 RPMs for this project. If you are not sure which speed setting to use to achieve 15,000 RPMs, refer to your tool user manual or check the 'Product Support' tab for your specific tool at Dremel.com.
Secure supports in your frame by placing 2 foot lengths of miter cut pieces of furring strip in all four corners. To do this, you will need your Saw-Max tool, a SM600 flush cutting blade and a miter guide. Place the miter guide flush against the furring strip. Clamp the guide in place. Rest the Saw-Max against the guide as you begin cutting and move the tool smoothly through the furring strip. Cut the opposite end of the furring strip at an opposite 45 degree angle so the piece can fit flush against the inside of the frame. Miter cut 6 pieces of 4' lengths in total and save the two extra lengths for step 6. Tip: The miter guide can make cuts at varying degrees. Here we are making 45 degree miter cuts.
Secure all four pieces of miter cut supports using the method in step 2.
Stretch a length of cloth 8 1/2' wide and 6 1/2' tall across your frame. Secure the stretched cloth using a staple gun. Tip: Secure the cloth slowly around all sides of the frame and ensure that tension is even across the screen. Pulling too hard before securing staples can create ripples in the finished screen. The best type of cloth to use for a movie screen is something heavy that is made to keep light out, such as curtain backing which can be found at fabric stores. To give your screen more of a reflective property, many specialty shops and online retailers carry projection paint products you can apply to this cloth.
To create a stand for your screen, cut a 2" x 4" by 8' plank of wood in half. Make a mark in the center of your plank of wood, 4' down. Cut on this mark using a Saw-Max and a SM600 Wood and Plastic Flush-Cutting wheel and the 2x4 cutting guide. Lay these pieces flat underneath your screen on the left - and right - hand sides of the screen as shown in the diagram above. Using wood screws, drill the frame to these legs. Add additional support for the legs by attaching one of extra miter cut pieces of furring strips you saved in step 3 from each leg on your screen stand to about 1' up the side of the frame. Tip: To cut a 2x4 - place the guide near your measurement marks. Leave about an 1/8 inch between the guide and line to accommodate for the kerf of the wheel and its slight offset. Clamp the guide in place. Make your first pass, then flip the board over to complete the cut all the way through the 2x4 on your second pass.
To reduce the risk of injury user must read instruction manuals for all tools used in this project. Wear eye and respiratory protection. Use clamps to support work piece whenever practical.