OK here is the finished project (well nearly it needs tweaking a little)
I picked up a NEC 500WS short throw PJ but it needs to be installed upside down (on a ceiling bracket) as the throw from the center of the lens is angled upward it works out to be 37" higher than the PJ itself so the image is way high if it sits on a surface.
If you lower the PJ to compensate you hit the back of the driver so installing upside down works great as it shoots down over the driver head.
I should be able to post some images in a couple of day after the ceiling bracket arrives.
The dimensions of the screen are 96" X 36" I used 32" for the center 29" each side the rest is made up in the bends and the frame.
I ruined the first board as I tried to bend it by scoring it then trying to bending without heating it first it just snapped.
The second attempt I laid the board on a table with 30" hanging over used a heat gun up and down and the weight of the board curved perfectly and held its shape.



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