So, I finally got around to started building... I got started yesterday evening... just thought I'd share what I have done so far.

The components:
2nd hand Minoten WUXGA kit
LL Ballast(old one)
LL Mogul
LL Pro Fresnels(I hope it is anyway, bought alot from a builder that never got started)
LL Pro Lens.
New LL lamp.
2 x 120mm Antec fans.
Nails, screws and wood.

Still needed:
a mirror(the one I got at first was in pieces when it arrived.)

The plan:
1. Build first, ask questions later.
2. When the fresnel/LCD frame is done, put the lamp behind the frame at the right distance. Cover with cardboard.
3. Hold lens by hand, behold projection by eye.

Hopefully I'll get around to building a wooden box if I ever get to step 3.
That wooden box should hold a mirror, hopefully bending the light at a 60 degree angle, very much like the P-Cubed by Punisher.

I know it might not be the best way to do it, just building with no plan, but if I start planning, I'll kill myself and the project. So... below here you'll find pictures and short explanations of what I have done so far.

/edit:
Won't let me change the title

/edit2:
It let me change the title

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This is the fresnel/LCD frame I built. Not closed at the top, still need to put in the fresnels. It probably won't be closed, but it will have support to stay somewhat stabilized. Planning 10-20 mm between 220 fres and the other fres(600?), and 25-30mm from there to the LCD.
So, it will be unsplit.

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Just a closeup of the screws... notice the pen I used, it couldn't draw a straight line... must get that one fixed

Next up was cutting the fresnels... I don't really know how much larger than the LCD they should be, so I just cut the at the same size. Crossing my fingers that the dead border and metal frame on the LCD is enough.
This might be an issue... any pointers?

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This is where you see the Fresnel in place, ready to be cut by me. I had a few problems getting it right, but I hope it works out.

Leftovers anyone?
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The result:
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And there is one more, very much like this one, so one picture will have to do.

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I'm not sure it shows in this picture, but I chipped the edges of the fresnels a few times, hopefully it will have little to no effect on the final projection.

That's it for now, hopefully I'll be back with more.
But between being a dad, and being newlywed, time might be limited(one of the reason for building quick and dirty, I wouldn't get anything done if I was too thorough).

You did cut off equal amounts from both sides of the fresnels right???

Like on the left and not on the right?

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Yes, I did that right... I imagine the lens shift would have been pretty bad had I done it wrong.

I'd say that amount of dead space will be sufficient. It's fairly easy to calculate if you know a little trigonometry or you could make a scale drawing. What did you wind up with? 3/8" of an inch extra all around or thereabouts?

7.5 mm is the dead space around the active part on the LCD, (3/8 inch is 9.5mm)... I am very close to that figure on the fresnels. Hope it's enough.
It might be just on the edge of what is doable, but we shall see.

Ok, allready I am deviating from my plan. I'm going to ask a question before I start building the lightbox.

My bulb is 46mm wide.
Should I make the lightbox 120mm x 120mm x 350mm and fit a fan on each end?
Or would 80mm x 80mm x 350mm be big enough?
Will the airflow be too restricted? will the fans have to spin at high speeds?(making alot of noise)

Bulb dimensions can be seen here:
https://secure.lumenlab.com/shop/product.php?id=57

The bulb is happy hot. There are myriad ways of cooling. Keeping the heat away from the fresnels and LCD is the trick. Some have sealed up their lightbox and used an IR blocker and used just one fan to cool the lightbox. I think you'll just have to scrounge through the plogs and see what's worked and find something close to what you're planning.

You can always make a crude mock-up out of some scrap wood or whatever just for testing purposes. Even cardboard can work for that purpose.

So... I finished the frame for the fresnel, and they are now mounted (pictures will follow later).

After the frame, I decided to testfire the lamp.
Everything is assembled(correctly I hope)
I turned it on, and nothing happened for a few seconds. Then it flickered a little, went out, and flickered again. I decided to turn it off, not knowing if this is correct. It had power for around 5-7 seconds.

What happens when a correctly wired bulb is turned on?

It is working now... just had to leave it on a little longer.

Thanks to Brainchild.

Ok, time for updates.

The lamp is working fine.
The LCD has been tested, and is working, however, I don't know if there are any dead/stuck pixels.

I finished the LCD frame, and painted it black, no pictures of it though, nothing revolutionary about it though.

The fresnel frame was modified, it was wobly due to assembly with screws(not recommended). Instead I used some superglue and some angled metal thingie, works much better.

I started the lightbox;
This was made from an old computer cabinet. I cut off the parts I couldn't use, and hammered the rest into shape. I pounded it around a piece of hardwood that was 120mm wide.

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And ended up with this.

I then rivetted(sp?) it so it holds the shape.

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Just one shown here, I used 3, it is quite stable, and should hold fairly well.

I test fitted one of the fans in the lightbox;

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As you can see, not too much of a gap around it.

I ran into some problems though;
I cut the computer case with an old scissor style cutter, and it has very rough edges... I need to find some way to make the smoother... must borrow an angle grinder or something.
Also, pounding metal without the proper tools makes for a very bad and bumpy box. It will do the trick I hope, but the handywork is... somewhat lackluster. I can live with all this though, since I am building this in an 3rd floor apartment, on the kitchen table with duct tape and superglue.

The box isn't exactly 100% lightproof where it is supposed to, so I need something to fill the holes... what do you suggest? can I get some sort of heat tolerant silicone? this definately needs to be fixed in order to contain the heat and light.

Another problem is that the box turned out to be too short.. or more correctly, the lamp + the mogul is too long.
I can fit the mogul + lamp + 2*120 mm fans in it, but only with a couple of mm clearance in either end. I could move the fans out, and let them stand out of the ends like so:

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But mounting will be tricky. We'll see what I come up with, but any ideas are welcome here.

I considered buying a piece of furniture from Ikea and build the projector into that, but it turned out to be way too expensive, so today I bought a 12mm MDF and I am building a box from that.
A friend has agreed to roof the building of the box in his workshop... it isn't much, but it is way better than in my kitchen.
Going to his house tomorrow to start building... wish me luck

I started the enclosure today, and boy, it is going to be big. Too bad I forgot the camera, but I will take some pictures when I go back... Sunday or monday.
I was nice to get started, and I was getting some pretty cool ideas while building. Mostly shaving the corners off making it nice and soft to look at.

My friend whose workshop I am borrowing solved my fan mounting problem, I am going to mount the fans onto the box instead of on the lightbox, kind of a no-brainer... but hey...
That solves one problem, but creates another. There is going to be a small gap from the lightbox to the fan since my build is so "not straight lined". My friend suggested duct tape, but I am dubious. Any suggestions? just more metal?

I still need some advice on what to do about the leaks in the lightbox, any suggestions appreciated.

Projection isn't too far away, can't wait to put on Ice Age and see this little fella laugh at the squirrel in the beginning(When we put it on he just laughs... it's great)

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