A common problem faced by projector owners is the humming noise produced by projectors. If the sound is too loud, it becomes unbearable and will ruin your viewing experience. The good news is that you can easily fix it with a projector hush box. Read on as we discuss everything you need to know about projector hush boxes.
What is a hush box for a projector?
A projector hush box is a structure used to quiet the noise produced by a projector’s built-in fans. It’s generally made up of a frame (mostly wooden), cooling fans, foam, and dust filters, each of which has a specific function.
Projector hush box design
There’s no standard design for projector hush boxes. But there are certain features that each model must have to work efficiently. Let’s discuss what they are:
Enclosure or Frame
A projector hush box is typically made from wood because it’s better at soundproofing than most materials including aluminum and is widely available.
Now, you may be wondering what measurements you should go for. The ideal size for you will depend on the dimensions of your projector model. But it should be bigger than the projector by anything between 3 and 6 inches.
If you build a frame that is smaller than that, heat will accumulate due to insufficient airflow and the fans will struggle to cool it down. This will cause your projector to keep shutting down as a measure to protect its components from getting damaged.
And if the temperature keeps rising, the box may become a fire hazard.
If possible, build two wooden walls to help insulate sound and therefore create a better viewing experience.
Remember to also drill a big-enough hole for projection. This will then be fitted with clear, anti-reflective glass to allow light to pass through easily. Any other material will cause reflection of light which translates to low-quality images.
If your projector comes with a remote, it may help to also drill a hole for the IR receiver so that you can use it.
Dimensions Examples
| Projector Model | Physical Size | Minimum Box Size | Maximum Box Size |
| Epson Home Cinema 1080 | 3.6 x 11.9 x 9.9 inches | 6.6 x 14.9 x 12.9 inches | 9.6 x 17.9 x 15.9 inches |
| BenQ HT2050A | 15 x 11 x 5 inches | 18 x 14 x 8 inches | 21 x 17 x 11 inches |
| Optoma UHD35 | 10.6 x 12.4 x 4.6 inches | 13.6 x 15.4 x 7.6 inches | 16.6 x 18.4 x 10.6 inches |
Cooling Fans
A projector hush box needs a way to dissipate heat produced by the projector. If there is none, hot air produced by the projector’s internal fans will stagnate and eventually cause a rapid increase in temperature. And as you may have guessed, the projector will automatically shut down to preserve its components.
That’s where cooling fans come in. They help circulate air around the projector and therefore prevent overheating.
Now, when deciding the size of fans to use in your construction, go for large PC fans. They tend to move more air in comparison to smaller fans while rotating at the same speed. Fans have a noise rating expressed in decibels. Be sure to choose the ones with the lowest rating.
Foam
Another important component of a projector hush box is the foam. Foam is normally lined along the interior sections of the box. It helps dampen the noise from a projector’s onboard fans by absorbing it or preventing the sound from bouncing off the wood and creating even more noise.
Acoustic foams are cheap and will set you back around $20 on Amazon and other online retailers.
Air Filters
Many DIYers overlook the importance of air filters and skip their installation. But they are as critical as any other component, especially if you set up your projector in a dusty area.
What happens is that dust accumulates and causes the internal fans to work harder to keep it out. The fans will become louder than usual and the projector will overheat leading to a random shutdown.
Filters help lighten the load for the intake fans by absorbing most of the dust from the air. The fans will work less, become less noisy and you’ll have a great viewing experience.
Projector hush box plans
We have selected two projector hush box plans to help you get started with construction. They are free and can be made by anyone with basic DIYer skills.
Coffee table projector hush box
This is one of the best designs we’ve come across. It has plenty of pictures, a YouTube video, and a good instructor, all without spending a dime. The instructor takes you through the entire process from cutting the wood to testing electronics.
You can read more about this design here.
Hackaday projector hush box
The hackaday hush box is equally as impressive but lacks the kind of detail a novice DIYer may need. It includes pictures as well as the most important information for building the box. ‘
You can read more about this design here.
Final Words
If your projector is too loud for your liking, it may be time to consider building or buying a projector hush box. We recommend building it yourself because it will be cheaper, and you can customize it based on your requirements.