I've been doing some tweaking with the light and the brightness of the image.

I have removed the front 330mm frensel and left the bulb/reflector, lexan, 220mm fresnel, and triplet in place to help diagnose the problem. It creates a "light circle" on the screen and helps with the aligment and placement of everything

Ideally we want the whole image to be in the "light circle". The only way this happens is if I have my sled with my 220mm fresnel and lexam about 13 in away from the light. When I move it only about 6 in from the light the bulb the "light circle" is condensed and covers a small portion of the image.

How do I make the "light circle" illuminate the whole fresnel without having the fresnel so far in front? This is way off spec.

You need both lenses. really.

Go back to the basic design. Use both fresnels, make sure they're correctly oriented, (220mm fresnel closest to light, grooved side away from the light, 317mm fresnel towards the triplet, grooves pointing away from the triplet.

If you can arrange this with the LCD out, you should get a projected image of the lamp arc where the triplet goes. When you have the lenses aligned like this, you will get all of the LCD within the "light circle."

This is the very basic projector design.