Hushbox
Hushboxes are a choice way of reducing projector noise in a home theater environment, especially in apartment living. My projector is particularly irritating because once it’s warm, it emits barely audible test-tone-like beeps. Forcing the noise to travel around baffles and sound absorbing foam is a great way to reduce this problem.
Features
Overall noise reduced 4dB, tones are now inaudible.
Magnetic bottom panel for easy access.
A single wall-mounted button triggers an Arduino based IR blaster to turn on projector and fan together, along with the stereo and motorized projector screen.
A thermistor ensures if heat is present the fan will remain on. This is handy if, say, the Arduino resets and “forgets” the projector’s power state.
Process
Several concepts were sketched, and the best ideas drawn up in CAD. A full CAD model was needed to get a sense of the aesthetic and manufacturability, and eventually needed for machining toolpaths for the top and bottom panels.
The scrap wood mock up proved this didn’t introduce a heat issue, and enough operating room was available around the projector itself. The exhaust side of the box got warm, but the projector itself stayed well within its operating temperature.
The top and bottom are made from CNC-routed cabinet plywood with embedded magnets hidden by wooden plugs. Many layers primer and spray-on enamel and hours of wet sanding give it the “manufactured” look I was going for. The walls are laser cut acrylic bent with a custom jig and a heat gun.
The original was hung from the ceiling; I’ve since adapted it to a wall mount for my current apartment.