How to Disassemble or Break Down a Large Projection TV
Do you have large screen projection TV that you want to get rid off? This instruction will give you a guide on how to break down and disassemble a projection TV into manageable pieces for disposal at a dump or landfill where the pieces and components can broken down further and have a chance for recycling.
This article with photographs uses a Toshiba 50H82, a 50 inch projection TV as a model. This TV had picture quality issues and repairs would cost almost the price of modern flat screen TVs. Large projection TVs are bulky and heavy. Getting rid of them can be expensive because the new High Definition TVs (HDTV) are cheap and nobody wants the massive projection TVs anymore. These beasts take up too much space. (See Fig 1)
Dismantling TV Overview
In my opinion, breaking down the Toshiba was not difficult. The design was user friendly for internal access. However, the case around the main components was glued. But I have a solution for destruction.
The TVs of today that uses LCD or LED technology are very lightweight. Even though I purchased a 50 inch LED TV with someone to help me, I really didn’t need the assistance. The box is large but there were two straps to handle and carry the box. I am not that strong but I was able to lift the box and move it around by myself without any problems.
Older TV use cathode ray tubes (CRT) to provide video and there have been large CRT TVs made to provide screen sizes up to 36 inches. However, newer technology came around to support even larger screen sizes to provide a big screen movie experience. One of the technologies that became popular during the late 90’s to early 2000’s, were the Projection TVs. There were two types of projection TVs in the market: front and rear. A rear projection TV looks more like a standard television set.
The rear projection TV contains a red, green, and blue (RGB) projector, which produces the images to the back of the TV. This projector can be CRT, LCD, or DLP. The Toshiba 50H82 model uses CRT projectors. The back of the TV contains a mirror, which receives the picture which combines the RGB colors into any color from the original movie source (from cable, satellite, disc, and so on). The image that is projected to the rear mirror is what the viewer sees in the front screen.
First, move the projection TV to a place where you can get dirty and make a mess. I used the living room at first to just remove all the heavy parts prior to moving it to a final disassembly area. In this case, I used my garage.
Gather all the tools needed to open up the case and remove components like large circuit boards. In the Toshiba 50H82, there were lots of small slotted lag screws. I used a cordless drill with an attachment to remove them.
Be mindful of any loose parts like screws or debris flying from using brute force during your work.
Remove Back Panel
I started the work behind the TV. There is a panel to access the large main circuit board. Unscrew the bolts or screws and remove the panel. (See Fig 2)
Disconnect Power Cord
There is a power cord connection that was not accessible with the back panel in the way. With the back panel removed, you can see that the power cordis connected to the main board. Disconnect to get the cord out of the way. (See Fig 3)
Loosen Main Printed Circuit Board (PCB)
Locate any screws that fasten the main board to the base of the TV. Unscrew all of them until you find that the main board is loose. Once the board is loose, you can start disconnecting all the wires. (See Fig 4)
Disconnect Any Cables and Wires from PCB
Note in the pictures (Fig 5a and 5b) that there are several cables and wires connected to the main board. You can just cut them with wire cutters or scissor or disconnect by hand. I started disconnection by hand in case someone wanted to put the TV together again. After running into some connectors that seem impossible to remove, I just outright cut them.
I imaging some scavenger trying to put this TV together so I thought I would make it easy to put back together. Unfortunately, the connectors were so stuck and I was running out of patience.
Put PCB Aside
After separating the cables from board, you can put it aside to work on the next step. (See Fig 6) As you can see it is quite large for a PCB.
Remove Front Panel
For the next step, I opened up the front bottom panel. I had the pry this cover from the side with a screwdriver. Once I got one area loose, I was able to work my way in separating the panel from the TV. (See Fig 7)
Removing Middle Panel
There was another panel in the middle to access the RGB projectors. Unscrew and remove this cover and expose the projection system and associated circuit boards. (See Fig 8a and 8b)
Remove Front Screen Part 1
We will need to remove the RGB projectors from the top. However, the large front screen is in the way and has to be removed. Ensure the large plastic piece holding the screen is unscrewed from the bottom.
This large screen slides up for removal. There are four ‘hooks” that hold the screen in place. (See Fig 9)
Remove Front Screen Part 2
Grab the plastic piece from the bottom and lift up. The large screen is bulky but not heavy. Put the screen aside and out of the way. You will see a huge area for the projection of image going onto a large mirror on the inner back of the TV. (See Fig 10)
Unscrew RGB Projector
Locate the screws that are holding the Red Green Blue (RGB) projector assembly from the top. (See Fig 11) Unscrew the projection system and ensure no wires are connected to the rest of the TV. If there are any connected wires, detach or cut.
Remove RGB Projector Assembly
The RGB projector assembly was the heaviest piece other than the large TV body. (See Fig 12) Put this piece in a box because there are many sharp edges that could hurt you. Put the box and the projector assembly out of the way.
The left and right speakers are held with 4 screws each side. Remove the speakers to lighten the TV. (Fig 12.5)
Smashing the Housing
Even with the main circuit board, front screen, RGB projection assembly and speakers removed, the hollowed out TV is still heavy and very bulky to put in a small truck. However, the TV is lighter for moving. You can now put the large TV in a big truck or van and get rid of it.
You now have the option of disassembling the TV body even further to transport the pieces in a small SUV or car.
The problem with the rest of the Toshiba 50H82 TV is that there are no other areas to unscrew. The remaining pieces are glued together. Brute force will be needed to break the rest but there is a large glass mirror to deal with.
The mirror slides out upward but the top of the TV is glued and in the way. I took a large heavy duty hammer to separate the left and right sides from the TV. The hammer I used is not the type used for removing nails on the other side of the tool. That hammer is too weak. I used the hammer akin to a small sledgehammer like the one Thor uses. (See Fig 13)
After removing the top, I was able to slide the large mirror out and put it aside. (See Fig 14)
Warning: This is glass. Be cautious when handling!
Breaking Housing Down Even More
I started removing the left side and right side with the hammer. After removing a few more odd particleboard pieces, all that was left is a piece that looks like a cabinet or table on wheels. (See Figures 15 and 16)
After making the large wooden pieces small enough to fit in your van or truck, you can neatly stack the pieces in the vehicle and transport to your local landfill.
If you desire, the particleboard scrap wood can be reused for making furniture. The husk of the TV’s cabinet can be converted to a table or cabinet for the new TV.
The Toshiba 50H82 50 inch rear projection TV has sentimental value. I purchased this TV around 2002 after my second kid was born and I knew I would be at home more to care for them. Having large high definition TV made entertaining kids and guests more fun.
Ten years later, the video started to get fuzzy. I was not able to play any console games like Nintendo Wii and Xbox 360 anymore. It would cost approximately $100 dollars just to have a technician just to come to the house to troubleshoot.
Leaving this goliath TV on the curb is just an eyesore. With HDTVs relatively cheap, why would anyone want an old projection TV that does not work correctly?
Goodbye, Big Screen Projection TV. You served a purpose well but newer technology has taken over. I mean some new TVs do not even carry the old RCA component or S-Video connectors anymore. HDMI connectors have taken over. Makes me wonder what the next ten years will bring with regards to television tech.
© 2012 Romian1