My new custom projector build

[Frixxion]

Hi everyone,

A while ago I started building my new projector. I planned on trying to make as many parts myself. I started with modeling the whole thing in Solidworks and came up with this:



Then I started gathering parts, which took me a while because I hadn't worked for like 2 month because of a broken ankle. But after the Haar-LEM I decided to get started with whatever I could get my hands on. So I started with the dichro mounts and mirror mounts. Up till now I only have 2 finished and I need to make one more dichro mount.

This is what the mirror mount looks like (bad pic, I know )


Last week I started on the dual red and bluray mounts and it was a pain in the ass. I took me about 3 hours of (hand) milling but the result is simply stunning . Today I finished up the second one and this is what it looks like:



Today I also started to drill and tap a few holes in my baseplate so I can run my projector (unfinished though) because I was tired of looking at a bunch of parts . I changed the layout a bit because I think this will give me some more room (and eventually I could cut the baseplate's size). This is what it looks like so far:









Any comments on how to improve this or comments are welcome!

I'll try to update as soon as possible

,Jordy

[Frixxion]

Forgot to tell but these are some of the (planned) specifications:

Scanners: DT-40Pro
Red's: Daedels 22x diodes
Bluray: PHR-803T's
Green: Laserwave 150 mw from Stanwax
Baseplate: 6082 Aluminium, 400x400x10mm
Mounts: Home-made
Frame: Steel, 20x20x2 square tubes
Optics: Dichro's PBS's, Mirrors from laserwave, stanwav


Red = still need to buy
Green = got it!
Orange = almost

[sbk]

Awesome work mate!

I really like to see a 3D modelisation and then the real building. And it's really useful. I'm making the same right now to redesign my projector

[ledfreak3d]

nice work finaly a new dutch build

[mophead]

Wow, I really like those diode mounts.

Nice work.

[stanwax]

Great work Jordy - just be careful with the diodes - there seems to be no insulation between the cans and if they are not isolated from each other as a pair or from base plate gound you may get some death of diodes. If the cans are cathode to case and the cathode is controlled by the driver (ie anode to positive supply) then if the whole assy goes to ground the diodes will have unrestricted current and will have you full power suppy right across them.

Rob

[buffo]

Nice work!

One issue I see is the total lack of adjustment for the dual diode mounts though. I suppose if your machining is perfectly perpendicular, and the diode output is perfectly parallel with the housing, and you can position the PBS cube perfectly, then you'll be just fine, but that's a lot of perfection required... Don't you think you'll want at least a little adjustment on one of the diodes?

Adam

[ledfreak3d]

Great work Jordy - just be careful with the diodes - there seems to be no insulation between the cans and if they are not isolated from each other as a pair or from base plate gound you may get some death of diodes. If the cans are cathode to case and the cathode is controlled by the driver (ie anode to positive supply) then if the whole assy goes to ground the diodes will have unrestricted current and will have you full power suppy right across them.

Rob

just use laserwaves small analog drivers then u dont need to insolate the diodes

[Frixxion]

Great work Jordy - just be careful with the diodes - there seems to be no insulation between the cans and if they are not isolated from each other as a pair or from base plate gound you may get some death of diodes. If the cans are cathode to case and the cathode is controlled by the driver (ie anode to positive supply) then if the whole assy goes to ground the diodes will have unrestricted current and will have you full power suppy right across them.

Rob

Thnx Rob for noticing this! I almost forgot about it . But I have not yet turned on anything yet and the modules aren't even screwed down, this was just for the picture. But I want to use some very old printing paper (you know, the old chain paper) because it is extremely thin. Would this work as insulation when I wrap it around the modules?

Nice work!



One issue I see is the total lack of adjustment for the dual diode mounts though. I suppose if your machining is perfectly perpendicular, and the diode output is perfectly parallel with the housing, and you can position the PBS cube perfectly, then you'll be just fine, but that's a lot of perfection required... Don't you think you'll want at least a little adjustment on one of the diodes?

Adam

Yeah Phritzler (phil) mentioned that to me on MSN as well. So I'm still working on a design for a very small 3 axis mount (inspired by SBK 4xred setup). I won't be doing this in Solidworks though, I'll just take my other mounts and shrink the dimensions .

just use laserwaves small analog drivers then u dont need to insolate the diodes

I'll be using the Stan_Ham driver I bought from anthony. He broke down his projector and I bought his driver board. However, I did cut the board's size to the individual drivers because I thought the whole board was way to big. So now I'll be stacking the individual drivers to save space

[stanwax]

What a shame Anthony split up that lovely little projector!

Yes the paper will do the job - paper is a pretty good insulator and certainly with the voltages involved here it should do well

Rob