Ok, well here goes my 5th and final projector. I sold 2, have two in use. So anyone saying DIY is dead is, well, you know. Anyways, this one, after doing all my others. I decided I want to be as close to lumens and size as possible to a commercial unit. No more saying we can't do it.

I am using mostly left over parts as follows:
1. 400w ushio retro and ballast, used 2 times on my large projector before going 895w.
2. Lexan XL leftovers from other projectors.
3. Rear 220mm that I pulled from my large projector.
4. Front 200mm that never used in my 5.6" projector
5. Clear glass, from prior projector projects.
6. Fans, wiring etc left overs.
7. power adjustable long lens. 100mm to 170mm focal. I bought but never used.

I will be using the 8.4" lcd 800 x 600 lilliput. I already have the pro reflector. Heat will not be problem hopefully, because I have designed a airflow that works great on my current projectors. One uses an overhead light, and the other the 895w bulb. Both with no issues. My goals will be to put the light, close to the final lens, which will bump output lux much higher. Here goes!

Sounds good to me. I'm almost ready to begin building my full-size 15" pj. Because of its size, I'm a little worried about the "wife approval factor". We don't have a room to dedicate to the projector, and will have to store it when not in use. I'm anxious to see a small diy pj with a good projection for DVDs. We're currently using a Buhl 108 OHP which has the 575W HMI bulb along with a Sharp QA-1400 projection panel. Good results, but I'd like better.

I believe with this setup, I can get over 500 lumens, closer to 1000 lumens. I want to be the first ever DIY. I sure wish I could get better than the 800 x 600 pixels, but I guess this will do. I will be placing it on the floor, directed to the ceiling. over my bed. No mirrors, just directly through design.

Welp, doing measurements, looks this way. It will be 20" x 12" x 10". I am going to try something different with the lcd and fresnels. I am going to run about 70mm to 100mm between the fresnels and the lcd. Thus, the light will be captured from a wider angle. It will then hit the lcd and on to the lens. But the light will be the same as a 10" or bigger lcd, since the fresnels will be larger, and then the light will shrink down before it hits the lcd. Just not sure how much bouncing around the light will do before getting to the lcd???? Will keep you updated.

Sounds like an interesting build.I will be curious to see your results. Good luck

Old projector sold, and Lilliput is ordered and on it's way. 2 weeks and I should be rockin and rollin'.

It's always good to see more small PJ's so i'll be looking forwar d to seeing how this one comes out especialy since your using a 200mm front fresnel. It'll be interesting to see the throw distance and brightness levels.

DM

I know the throw will be very short, maybe even 5-6 foot for a 100" proj. My tests of the lens this weekend were out of this world. I can't wait, let's just say my projector I just sold with this lens gave me some lux numbers people wouldn't believe, using an overhead proj light bulb. But my expectations for lumen output is very high for this new lilliput. The highest of any diy. The closer you are, the brighter the image, as we all know. This is viewed at an angle from my bed, so the projector will sit over my bed at the foot, (hopefully won't fall) and the projection as at the side of my bed, so no problem with the projector being in the way of view. Eventually, when my daughter won't mess with it, I want it beside my bed facing up to the ceiling, so i can watch tv above me

Went and picked up 2- 120mm fans ac120v, they seem to be kinda loud, but move air pretty good. I am gonna have to see how loud when in the box. I believe I can use a dimmer to slow them down if necessary. I wanted 120v, so I would have less plugs to mess with. Also, these will both be pulling air out. Placed right behind the pro reflector, to keep it and the condensor cool. The box will have an opening on both sides of the lcd, that lets the air flow by, letting the lcd cool, and pulling all hot air out. It worked really well on my last halogen lit projector, so I believe this will do the same. The lilliput is suppose to arrive Thursday, I highly recommend this place to get your lilliput, it was super fast shipping and a good price. The only issue is that it has a language box pop up, so I just keep on clicking cancel without problem. http://www.ex-audio.net/shop/product_info....products_id/152

All that is left to get is some plug in wires, and the wood.

Lilliput just arrived. That is grade A service, fast shipping etc. Can't wait to start tearing it down. Here goes.

Edit: Wow, that thing broke down easy, and is very see through. i think this lcd is gonna be awesome. Removing AG now. No cable issues.

where did you get the lil from ? and if you don't mind how much ?

fw

http://www.ex-audio.net/shop/product_info....products_id/152
I think it was $30 shipping, but it came in 3 days. Also, just got done with the Front AG, the rough side, 2 hours water rag soak and came off with no issues. I don't think I will remove the rear, since this lcd is so clear. I think it lets atleast 10% through, but will test it with the lux meter.

Quick test last night on the lcd. Not more than one point, so probably a little off, but close enough. 61000 lux sun, 5100 after lcd. Not as high as hoped, but still good enough.

Also, figured out the specs are wrong on the lens. I have to place the lens about 280mmm from the lcd, so I am now going to use the 220mm/310mm fresnels. I think that is good, since I was kinda worried the fov of the lens was gonna be tight. I also figured out the long throw adjustment on the lens, so I should have some good adjustment abilities with this. Can't wait. Should have it done in a week or so.

Box is twice as big as I wanted, but decided that better big at first, and cut down later, than making it too small and having to start over. Anyways, tried cutting my finger off this weekend while doing it, so I only got the box nailed together, no light or stuff put in. Hopefully this week I will finish.

Sounds like your build is going well, have been gone for sometime and I am trying to catch up. How about some pics?

This weekend I will get some up, if I don't finish. I am hoping to get completely done though. Then I will have lux readings and everything else posted.

Can't wait to see the box, not the finger!
That is a good price on the lili.
Good luck.
Bluto

Here are some prelim pics. Now, as you will see, everything I started with, has been thrown out the window. Here are new specs, and this is the reason. I am only interested in lumens. Edited: I am shooting for over 500, for reasons that most of us know. So no folding, no long throw etc. It is a short throw, guessing around 6 foot for a 90" screen or so. I decided fiberglass is too hard, for adjustments. Box is much bigger than previously wanting, since the light is gonna be vertical for more brightness. The fresnels are now, 200mm rear and 300mm front, lens 280mm short throw wide angle. You will notice a slot at the bottom, where the lcd goes. This is going to be my invented wind tunnel. I did it on my last projector, and it worked good. So this time I wanted both front and back. What you do, is cut a hole on the top of the box, it lets air go through. The air travels in the rear of the lcd, between the fresnels and lcd. In the front, it travels and goes through the hole at the bottom, thus both sides have cool and fresh air traveling past the lcd. Then, there is no fan blowing in, just 2 120" fans 120v sucking air out the rear of the box. The air will travel right past the light, and pro reflector, thus keeping everything cool. With having the lcd so close to the light, I need as cool as air as possible. Plus, will be adding a condensor when I have the funds.

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Lens tossed, worked well on my 5.4" screen, but horrible on my 8.4" screen. I cut the box off, and am gonna use the plummer lens from SS. I have to go see what it says, but I thought it was 290mm focal. Has to be 229mm instead. So now, again, fresnel change. 220mm front, 200mm rear. Now i know I have to order a condensor as well, because only gonna get about 300 lumens as it sits. Plus, I will be overdriving this lamp until it blows. Then getting a 1000w short arc lamp. Nothing like the 1000w bulbs. I don't care what anyone else says. Nothing comparable in brightness. My theory on condensor, is that if I can control the same amount of light that would have gone into a 17" screen, into this 8.4" that I can equal the brightness, plus, having the light so close to the fresnel and box so close to the wall is where I will get the 500 lumens.

I just rewound this thread a couple of hours. Play nicely.

DJ

Thank you. I appreciate it. Just to clarify for further reference, I am not sure on any of these lumens. Just goals I have set for myself, and theories I have come up with the help of ArizV. I do have a lux meter, and will post values up as soon as I am done, please be patient. Thanks again.

Pics will go up this week. I can watch a 60" screen in the middle of the day, very comfortably. I have found, that 200 lux above whatever the current ambient light is about right. I don't know how good it could be with more, since I moved my light forward, and the lcd blackened from too much heat. So, I would have to say, I am about maxed of what I am gonna get, so I will run lux values this week and post them as well.

Welp, gotta go to the computer store. i broke a fan, I hit it with the reflector bolt, and wam. I also have to grab some more fan covers, since I tore two apart for the condensor holder. The condensor is just a lens I had laying around, so I figure a real condensor will improve the brightness, but not sure. The lens I have I am sure will crack after using it more than I have. I just fire it up, and turn it off to see what the picture looks like. Without the condensor, I ran it for about 2 hours, so I still haven't broken this thing in yet. Also, the ballast now is running with two 30uF caps, up from a 55uF standard. I am gonna put on 4uF more I think. That will give me about 60 lux more, and will be about 485watts. That is about it. It doesn't look pretty, I made some errors. One thing I knew when I did. I mounted the plug ins, and sure enough, the lcd had to be flipped. I had to put light blockers, since the light was hitting the lcd and turned a corner yellow alittle. Little issues here and there, but it is better to watch than my big one now. So now I have to start working on it again to get it up to par.

465watts approximate, 9uF over standard. Was 55uF, and now is 64uF. Screen is 46" wide 35" tall. This was before the made condensor. It did not seem to change the lux at all, so I decided to pull it and wait for a real condensor. Here is the deal though. At 75uF and 550watts, this would put me at 506 lux in the middle. I gain 15 lux per 1uF at this size projection. I don't think the ushio will take that much power, but when I get the 400watt bulbs like AV is working on, I can do that, and even using a better reflector as well. Then adding a condensor would atleast give me something. So I would be over my 500 lumen mark. All in all, pretty good setup. I do have some issues to deal with. This brightness is ok, but my lcd is warm in areas. I am gonna have to put a fan on it if I go much higher.

223 270 198

284 351 216

255 323 225

1.04m x 260.55 = 271 ansi

Arc is 5.5" from the rear fresnel.

I am considering doing the 75uf Cap, just to get me the 500 lux, so I can say I did it. I am just worried about the bulb life being 5 seconds. I don't mind too much since it is cheap, but really don't want to be without the projector right now. Will keep you updated. Although I know when I get the hqi bulb, then I can run it without worry.

Pic of my test caps, it will be placed inside obviously, but just making sure everything is cosier.

Top of my box. It looks like there will be a lot of extra ambient light produced, but not the case lux meter reads 1 at screen, and also there will be a black screen I am putting in the slot when I am all done, so you won't be able to see in and it will look nicer. This lets air flow front and back of the lcd.

heheh those plasma conduits look well connected to your gel packs there,,

geezz i threw out last year about 50 oil filled caps like those thinking i will never use them,,, oh well

Last night grabbed a speaker system for $25 at Walmart. Sounds good, came with a small sub and 2 small speakers.

I have two 400w normal ballasts, and I have been trying to decide, the money I will get from them is probably small, so grab the caps from them and toss the ballast, or sell the whole thing. Hmmm, decisions decisions.

More pics. The inside will look like crap to most, but I suck at making my stuff look really nice on the inside, The outside will look good when done though. As you will see, I have the napkin holder behind the 400w ushio, and it is cut down enough to bring the ushio closer. I tested without the cut, and with the cut and the reflector moved up 15mm and it is much brighter with the cut. I couldn't seem to get the focal into the light right without cutting it. The edge would have been touching the actual bulb.

Top of box. This will look better when screen put in, and box is colored

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Done while moving, so it looks kinda wiggly.

last one, not sure but these came out really wiggly. Must of been my movement or the screen. The proj is crystal clear. i am gonna do new pics this weekend in the other room with the camera braced. These are roughly 60" diag screens I think, unmeasured.

I really like my ebay Logitech X-530 5.1 system so far. It's awesome for the price.

I'm looking for an inexpensive 5.1 setup now that I can easily connect to my PC which is in turn hooked to the PJ. The logitech 5.1 systems came to mind first, but I only know one person with one of the most expensive logitech systems (the $500 one I think). good to know the X-350 is a good alternative. I can pick up an x530 for 55-60 shipped, or a Z-5300e for around $120.. any idea if its worth the extra $$?

edit: ok after reading some reviews I think I might plurge for a Creative GigaWorks ProGamer G500

I got my X-530 on ebay for around $30 total shipped!!

Take note they're not the best thing out there but maybe the best thing out there FOR THE MONEY.

If your tastes run towards high quality sound then you might be disappointed?

It's your wallet. I'll bet somebody here has the Z-5300e. Try a search?

ok for $30 I would buy it regardless of sound quality.. I'll have to peek on ebay

I'll end up splicing the wires though to extend the front speakers

New pics, but somehow my camera is messed up. It is giving these weird lines all over the pics. Not sure what it is. But just as an FYI this projector kills my large projector. We moved it into the family room last night, and my wife no longer wants to watch the large projector. But I told her I was gonna get the other one working as good. She gave me the eye roll.

All of these pics will have the lines???? Not sure what is going on with the camera. But not on the actual projector.

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hey those lines are almost certainly caused by misalignment of the fresnels in relation to one another. Its called the moire effect..sorry i havent read the beginning of your plog and jumped straight in to help. but check that those lenses are in as perfect aliognment as you can get them!
hope this helps

I forget who I bought them from. Check my plog for my fairly extensive mod of the system. It's easy to extend them but a pain because the controls are in the right front speaker.

Thanks for the info. But, they aren't evident at all on the projection itself. So I don't plan on messing with them. But the more I look at it. Look, they aren't the shape of the fresnels. It is the angle it looks like. I am gonna retake pictures straight on. I have more pics I don't have posted. I can see from the pics I took, the further back I am, the less you see that, and the clearer the pics. If you look, all the lines are on the side of the camera. I didn't have any of them on my other projector. So I think it is the light reflecting, since this projector is so much brighter than my large projector. I will retake some from the front and we will see. But since I don't see the lines, except on the light colors, it makes me think it is the reflection. either way, this projector is the best out of all the one's I have built so far, and since it is only evident in the pics, not in real life, I don't worry to much. :-) As an FYI, I almost gave up and was gonna buy a lcd TV, since I was happy, but not completely happy with the large one. Then I finished this one, and I looked at my wife, and said, welp, guess we don't have to buy a large screen tv anymore. She said yup. ;-)

This is pretty much the speaker system. It looks alittle different, but may be the newer model or something.

Just a thought about those lines....I took some screenshots a while back and had a similar thing happen. The lines didn't show on my projection either. Turns out the camera was picking up stray light from the projector. I repositioned the camera, and the curved lines no longer appeared in the photos.