DIY Projection Screen Masking

Written by david lipscomb Google
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DIY Projection Screen Masking
DIY screen masking can be a quick and effective treatment for home theatres. (home theatre with big flat television panel image by Pavel Losevsky from

Although most movies incorporate masking in the form of letterboxed images, true physical masking dramatically enhances contrast, making images truly pop. Using simple materials, the DIYer can create this masking, mimicking commercial offerings at a fraction of the cost.

Skill level:

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Things you need

  • 4-foot by 8-foot plywood sheet
  • Three yards of double-sided velvet
  • Heavy-duty Velcro
  • Flat black paint
  • Spray adhesive
  • Scissors
  • Circular saw
  • Measuring tape
  • Assistant

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  1. 1

    Measure the horizontal width of the existing projection screen, frame edge to frame edge. Transfer these measurements to the plywood sheet.

  2. 2

    Cut the plywood sheet using the circular saw, making two strips 9 inches in width, and spanning the screen's width.

  3. 3

    Paint the two plywood strips with the flat black paint. Allow this to dry.

  4. 4

    Spray adhesive onto both the plywood strips, and the backing of the double-sided velvet. Wait a few seconds for the adhesive to become mildly tacky prior to applying the velvet to the boards.

  5. 5

    Wrap one layer of the double-sided velvet material around the plywood strips, smoothing wrinkles and ensuring tautness.

  6. 6

    Trim any excess from the edges of the strips. Stick the heavy-duty Velcro to the masking panels and 12 inches of the upper and lower vertical portions of the screen framing.

  7. 7

    Attach the panels to the screen. Adjust them as necessary to conform to the movie's aspect ratio.

Tips and warnings

  • Place the soft side of the Velcro on the screen's frame. This will absorb more light than the rougher hook side.
  • Confirm that the existing wall mount hardware is suitable to support the screen and the new masking panels.

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