First I'd like to say thanks to all off you for your help, especialy Brainchild. I don't post pictures of the progress cause I don't think that I 've done anything new that can't be found at other posts. Exept the bellows maybe, but since its not yet perfect I will post when its done. The only big difference in my pj is the fan position. I finally did it the way I think is the best. With three fans. See picture bellow. The concept is based in a simple physical rule that says that hot air goes up, and that lcd and lamp needs the extra cool air. The results are amazing. The tempered glass is almost... cold !!! The same goes with lcd.

picture 2

can you post some drawing for your design for the cooling fans

You should have 2 fans blowing out and one in. Otherwise your are pressurising your box and that will have a negative effect on the tempurature.

I agree, less positive pressure (or negative) is better.

Since the box has a lot off holes there is no problem, hot air goes up by himself, the OUT fun it is smaller cause it is barely needed.

Hi Pentheas,

Make sure you take the temperature in many different sections of the lcd and at least one hour running.
I had a similar setup, what work fine for a month until appears a vertical blue line in the lcd, It just happens after while, one or two hour.
The problem is, some areas are very cool 78F (front center, direct front of the fan) and other reach too hot 105F (front bottom corner and back bottom center).
I’m trying to solve it now. Maybe you have that solution. If so, please can you show or drawing your design?.

Thanks

I will post some pictures when I have the time, although I thought the second picture tells the story, for now let me try to describe my design. The rear 100 mm fan is on the corner next to the lamp, it sucks air in. The second 80 mm fan is at the top, sucks air out, and it is placed between the lamp and the tempered glass. Now, the third 100mm fan (who does all the job) is placed right above the lcd, and covers also the two fresnels. After two hour projection: tempered glass is almost cold, so does everything else. The big vertical hole you see is after the tempered glass, and I have also made holes left and right to the 80 mm fan. If something changes in to the future, I let you now.

Pentheas:

Don't you find all that light leakage distracting when you're watching the screen, or is the projector positioned behind you ?

menuball:

Yes, it is positioned behind me. But since I took that picture I have made some changes and the leaks are minimized.

Hi again.
Almost a year that my pj is running, and my tempered glass... wich is not actually tempered (althought I have since then bought one for backup) is still doing fine... thanks to my fan settings that is !!! I strongly recomend that you should try my settings. No need for the first glass to be tempered since its almost cold, and of caurse longer life for the lcd. By the way I have viewed over 200 DVD movies since Sep2004 ! The only problem is that it gets dusty inside the box, but it seems that it needs cleaning only once a year. If I find an air filter that doesnt cut the air so much like those I tried, it would be perfect.
Take care.

yeah nice work on the cooling system. however those photos are very basic and don't show the airflow or.. anything really. otherwise that'd be a perfectly good air flow system for me to copy

If you have a specific question I will be glad to anwser it

Hi all,

Today my PJ died because of an... error of my behalf. I was just dealing with the six month dust inside the box and by mistake I droped the LCD, resulting a teared FFC cable. Its been three years since I built my PJ and over 750 movies (thats the oficial number I have actualy rented from a dvd club) ! Its been a while that size became an issue and I was planning to invest on a prosumer PJ anyway and now that HD 720p are out there under 1000$... I needed progressive anyhow for my work.

My homemade little monster will be missed. Good luck to all.

best
Pentheas

Damn, that's a real bummer dude. You should build an HD projector.