I whipped up some CAD layouts of the setup. I can go 5 foot high on the screens and allow for decent projection overlap between the projectors to be blended in with Sol7. That leaves a 1.5 foot of dead area above and below the screen.
I need to design a modular screen that I can put together and break down that will fit a 10x10' footprint and also have the mounting hardware for the projectors overhead. You mentioned using piping. That seems like it should work. Some sort of extrusion or piping would be easy to shape with a pipe bender.
My simulator is much larger than this, but I can work out all the bugs at my leisure with this size of a screen prototype. I also wish projectors could be used in portrait mode. This would make the screen design easier to accommodate the projections at full height but the cooling on projectors prevent using them that way.
Initially, I'll target 3 projectors for 180. If that works good with the design I'll later add in the rest of the projectors as I can afford them. With this layout it makes more sense to stop at 5 projectors and not worry about the 6th.
Now that I think about it, how screwy would the FOV be if you went past 180°? I'd think you'd need the game engine to render screens 4 and 5 differently rather than just the normal "bending" that happens with the 3 screen angled setup. Wonder if you can map the look left look right to screens 4 and 5? (I'm not much of a sim player) But i can see 5x1 setups being screwy in FPS style games now. hmmm
I'll use this almost exclusively with flight simulator games, so that shouldn't be too much of an issue. Most flight simulators are good about custom cameras. I've also seen people using FPS games with panoramic screen setups too. There are a few example videos on YouTube.