Hello, its been awhile
Tonight I tested what I thought was good material for rear (or front) projection- plastic table cloths. Now you can buy this at any party store or walmart/target/etc. and maybe even in the $0.99 stores. As such, I got these at walmart: $0.97 for the black, and $1.47 for the white 3pack (they ran out of white singles). They measure 54x108, so if you will probably need to trim but they are so cheap if you mess up it'll be only a dollar to resume. I usd my garage for testing with two projectors: An Eiki LC-X990 which I got at a surplus store (with working bulb) for $35. It has a lumen strength of 2200 lumens but considering the age of the projector I can't imagine anymore than half by this point. The other is a nearly new Optoma PK201, which has only 20 lumens. I shelled out $100 for this baby used (I almost bought its newer cousin for only $40, but didn't). The resolution of the Eiki is XGA, 1024x768. The optoma is 858x480, which is native DVD quality.
The connections are clips burned onto a thumb drive and played via a Viewsonic media player, which is connected to the Eiki via component. The files were saved onto Optoma's internal hard drive, so external media player was needed.
I used a clip from This is Halloween song from Nightmare Before Xmas, Madame leota from Disney, and Hallowindow 3.
The sheets were stapled from the top and placed side by side. I noticed that they are very light, much lighter than the shower curtains so in moderate wind they could easily tear unless you secure them very well. i also notice that the white will hotspot, perhaps not as bad as the frosted curtain liner.
From the inside of the garage
From the outside
With the Eiki- notice the hotspot glow
Note that the black cloth handled the 1000lumen or so image, so clearly it can work for people who want to project but don't want guests to see a projection screen.
This is Halloween
You can see that the black, not surprisingly, eats up a lot of colors (and pop of the image) so if you want to project on black it has to be white or at least very bright projections
Here is the Optoma, resting on top of the Eiki
As you can see its very small, just slightly larger than an iphone
From the same distance, I was able to get a similarly sized image, around 88x48 from 16t away. But I past the max I could focus so the image was a little blurry. Pushing the throw down to 11ft, I could get a 32x58 sized image and good sharpness.
Surprisingly, the image is quite good at this size, the the colors play pretty well on the black as well as the white
also notice hotspotting has been reduced.
Here is a good representation of a tiny 20 lumen projector ability to project a good image in spite of it low lumen rating. For people with low lumen projectors you will have a visible image to project. But resolution is also important so images coming from other projectors with lower resolution might have blockier images to contend with at this size.
Hope all this helps for projection options this Halloween