Any one using led driver circuitry, or are you trying to run the LED's with raw DC? I see you are trying to use resistors, and these just waste power here is a good site for the extreme expenrimenter.
I'm going to try to build a LED backlight kit that puts out some real lumens that is efficent, however I don't know how fesable this is.
1) Proper driving of LED's you can vary the brightness of the leds with proper circuitry, and it's cheap just need to build a kit.. Here is the LED driver I'm thinking about the circuit's simple, and alot of your experiments require high current. I was looking at this driver.
http://www.maxim-ic.com/quick_view2.cfm/qv_pk/52662) Led's aren't point lights, and they aren't columnating either. This really beffudles the optics in the projector designs you have here. I see that people are trying to use the light directly this doesn't work either.
3) Heat management. Yes leds do create heat especially high powered leds, there needs to be a cooling arrangment. If there is none then the LED's will last no longer than a MH, or any other bulb. Remeber the whole idea with the led, is long life. In an array you can loose a few leds, but loose to many then there will be unacceptable hot spoting of the image.