My son approached me with a project: build a frame to fit over a flat screen TV with a plexiglass cover. The TV and frame would sit flat on a table. Okay…but why?
His answer: to play board games
I responded: so how does that work?
His answer: you connect a computer to the TV with an HDMI cable and view an image of a game board. Then you move your pieces around on the plexiglass cover.
My response: why not use the board that comes with the game?
His response: some games are completely digital and don’t have boards.
My response: so why not just play the game on the monitor?
His response: because with this method you can use customized game pieces that are scaled to show the difference in size between a scrawny little hobbit and a 20 foot tall orc. And you can hold the pieces in your hand. The game board can also have animations like a flowing river. It’s just a lot cooler than playing a straight up digital or board game!!
My response: Got you!!
So let’s talk about specifics. How big is the TV? Where do its cords come out? How is it vented for cooling? What is the distance from the screen to the plexiglass?
We got the TV out on a table and determined that if we used 2×4 lumber and made a frame 24 1/4-inch by 39 1/4-inch, that would fit over the TV. We would add 1/2″ thick plywood brackets at each corner with felt pads( to protect the table it sat on). The brackets would elevate the frame 1/2-inch off the table providing a 1/2-inch vent around the perimeter. We sanded the frame up to 220 grit sandpaper after filling some of the imperfections in the 2×4’s with wood putty made up using the sawdust from the sanding and Titebond II glue. We painted the frame with a primer, two coats of black acrylic paint and topped it off with a clear coat of acrylic.
My son picked up a large sheet of 1/4-inch thick plexiglass from a big box store along with a plastic cutting knife.
The width of the plexiglass was perfect, but it was too long. Using a straight edge, we scored the plexiglass along a line to give us the 39-inch length we needed. It was recommended to score over the same line 7 times, but we went with 10 scores. We put a board under the plexiglass at the scored line and cleanly snapped off the extra length.
We drilled a 1/8-inch hole at each corner of the plexiglass, set the plexiglass on the frame where we wanted it, and using the holes in the plexiglass, drilled a pilot hole in the wood at each corner. Using some wood screws and fender washers we attached the plexiglass to the frame.
My son attached some felt pads to the back of the TV to elevate it off the table for better ventilation and to bring it closer to the plexiglass. If this works, we are done. Later we may elevate the plexiglass off the frame with spacers at each corner and the middle of each side to provide for better ventilation.
I was concerned that all this plexiglass would be a static magnet for dust. My wife suggested that my son wipe down the plexiglass with anti-static dryer sheets and she retired to the sewing room (her woman cave) were she knocked out a large muslin bag with a draw-string closure to store the frame in.
In retrospect, you have to weigh the pros and cons: a really cool computerized playing surface weighing several pounds and costing several hundred dollars versus a 12-inch by 16-inch cardboard box weighing less than a pound and costing $70 for a pro edition. Cool wins!