Hi All,
Oh interest in the design

To answer a few questions.. SEE MY BLOG FOR THIS DESIGN!
The dimension are written on the design there.
The LCD is a 15.4" WUXGA (for 15" panel this design shrinks even smaller.)
The bulb is from a dukane 680..
As for light leaks and glare, you are correct, if this design was built as it stands, you'd have loads of issues, but you need to imagine that the box is split into 3 sections.
1 containing bulb.
1 containing top fresnel, top mirrir and projection lens
1 containing the bottom frensnel and window into the light box.
All the angles are very sensitive, this is why the entire mechanism is mounted on threaded rods, and everything can either move in all directions to some degree, or is clamped and welded into very accurate positions. For example all the frames containing the fresnels and LCD are made of aluminium square section, and those cylindrical tubes at each corner of the frames are drilled through using a bench stand... Accuracy will be vital.
At some point I will upload a finished sketchup diagram, and will make the sketchup file itself available for download.