by BHawthorne » Fri Aug 23, 2013 10:12 pm
The thing I've constantly found with traditional screen material is that it doesn't like to conform to a curve or conform to a really wide span. I've also tried using 3M adhesive to apply screen material to plywood backing and it turned out bad because the adhesive did not want to adhere uniformly and formed air pockets over time because the wood backing allowed air in from the wood breathing. Maybe if the wood was sealed and primed before application that might address some of that. I think if you end up using a traditional screen material that you'll have to tension it on the edges probably by stapling it to the reverse side of the material you're stretching it to.
Right now I'm leaning towards recommendation of a screen paint of some type merely because of the negative properties of screen material in this type of design. So far I've never been truly happy with any traditional screen material in this sort of setup because all samples I've experimented with have exhibited at least one or two negative characteristics. Bowing under tension, ripples, non uniform tensioning or air pockets. At issue is I've been so focused down on experimenting with screen material samples that I've yet to gain any personal experience with screen paints.
At best I can only give second hand information about screen paint in relation to DIY AV forums using it on flat screens. This might be where your build could help the sim community by giving new insight on screen paints through experimentation. I wish I could be more helpful and insightful on screen paint, but it's something I've really not had a chance to properly get experience with yet.
At this point I would suggest thin plywood or MDF sheet with a lumbar frame. Mud and sand the screen surface joints as needed for a uniform finish. Then prime and paint it with a DIY AV screen paint formula such as Black Widow. If you can find sheet material in 144" width so you can have an uninterrupted screen surface that would be preferable. 144" is the widest I've been able to find source in the US so far when looking around. Not sure where you're located, so no idea if that is possible in your area.
Even though I've been revising my screen builds since 2009, I still consider what I have right now to be experimental and not ready as a consumer design. Most of that is to do with screen material negative characteristics in this sort of configuration. I really think screen paint might be the best answer for now.
-Brad