New answers tagged trim
The "mysteriously gigantic" nailers are probably 15 gauge trim nailers similar to this one: Sounds like the one that you have is a finish nailer, and is likely a smaller gauge and uses nails with smaller heads. Thus less driving power required and a smaller gun. A trim nailer will generally give you better holding power, but also higher possibility of ...
This seems to be a design and/or shopping question, that is completely dependent on personal preference. You could trim the hole out with wood, some type of metal or plastic flange, some type of port hole from a ship (if you're going for a nautical theme), etc. The options are only limited by your imagination.
I guess I don't understand the problem. If you are making a projection port, why would it look funny? The standard professional projection window is fairly innocuous, even when used with a humongous projector: (From http://neiloseman.com/?p=3222) Here are two which are much larger than you might use for your application: (From ...
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