The principle behind a hushbox is to enclose you projector so that the fan noise has a difficult path to escape. Obviously you projector needs to breathe so you will need some active cooling fans. I chose super silent large diameter ones to give enough airflow. Then ordered some sound insulating foam to line the interior and make the partitions. The window glass is high transparency low IR glass from endmund optics. but you could almost use anything. The Body is Glued Up Plywood sanded nice an fine then stained and lacquered. To get a nice finish you need to sand with fine grit in between each coat, 3 or 4 coats and your good. Now my Projector is Much Much quieter. :-)
First off, very cool project! Came across it and immediately had to build one, (just ordered a BenQ w1070). So kudos to you.
Just a few questions:
Is this the glass window you used? If not, which one did you use?
Next, could you point me in the right direction for sound insulating foam? Did you order from "thefoamfactory" or a similar site?
Additionally, how did your intake and exhaust fans turn out when paired with a 12vdc wall wart? How loud are they? From what I've read, some people use 9 or 6v dc power supplies instead to slow the fan speed and thus reduce noise. And where did you purchase yours?
Finally, with a box encasing your projector unit how does your remote control communicate with the device? I'm assuming yout projector may just power up when it senses you've selected it's source on your amplifier/receiver.
Any help would be appreciated! Thanks