To make a black and white mask suitable for the surfaces editor:
Set up your projector beam to cover all the structure you are mapping
Open a new document in Photoshop with a white background at the same size as your projector resolution
Drag the tab for the new window onto your projector
Enter Full Screen mode (no menu bar)
Set zoom to 100%
Using the pen tool click on all the vertices of the structure you are mapping, or if it is complex with curves, trace a bezier outline.
Set the foreground color to black
Open the paths window
Stroke work path using pencil tool
You should now have an outline drawing of your set
At this point it's probably easier to exit full screen and drag the document window back to the main Photoshop window and re dock it by dragging the title bar where you dragged it from when you put it on the projector.
Create a new Layer
Using the pen tool trace the area you want to make the mask for onto the new layer
In Paths click on work path and make selection
Create a new layer and using the drawing you made on the structure as a guide select the areas you want to project onto.
Fill this selection white
Inverse the selection
Fill this selection Black
Deselect
If you want to soften the edges of your mask gaussian blur the whole image
Save as .jpeg with a meaningful name. I always include the pixel dimensions in the name so I know what size surface it is meant to fit
If you want multiple masks for different surfaces then switch off that layer and repeat with a new layer for each surface.
Finally save the Photoshop document as a .psd so you have the original tracing and all the masks layers you have made in 1 place so you can return and easily modify the masks or make new ones.
Mic