I thought I might post some pics of my final results. This is a 19" unsplit widescreen projector with the pro-lens and 550 and 220 fresnel combo. Very happy in the end and thought I should give back a little. Click on images to open larger link. (link to outside image host.)

The most important part in engineering my projector was COOLING the 400watt Ushio bulb.

I have a Scythe S-FLEX 48cfm (silent) fan blowing in from the front across the bulb tube. Then inline on the back is a 110cfm fan exhausting the hot air out. The exhaust fan is more powerful than the input fan to keep the box with negative pressure, so the upper cooling circuit works, and no matter what hot air will not billow up to the LCD. My running temps are 100 farenheit below the XL-10 and 78 farenheit between the LCD and 550mm fresnel.

Air is drawn in from the back vent, then down through the maze of 'shelves' holding the LCD then the 550 then the 220 and finally through a hole in the XL-10 in the corner and out the back. To benefit the cooling further, I kept the magnetic ballast outside of the box (runs very hot) and cut a hole behind the projector so the exhaust vents out into another room (furnace\laundry room)

Focusing solution was to use a 4.5" toilet flange and wrap the outside of the lens in wide electircal tape to friction fit the lens in place at focous. Long end of the lens facing into the projector box. I've seen some remarkable solutions to the focusing issue but my motto is KISS. Only need to focus it once anyway.

Extreme closeup of Player menu (shaky hands)



Guts of projector



Cooling curcuit (holes sides alternate between layers) eg. top layer on right, middle on left, bottom on right etc...



Here is my unsplit measurements with a 19" widescreen monitor, LCD first then 550mm condensor middle, 220mm on bottom



projected picutre size of 80" x 50"



Test shot for comparisson



Hi-Def National Geographic Wallpaper (no hi-def devices available)



Distance from rear 220mm fresnel to bulb top of arc tube is 20cm with Ushio SD400

Shot from LOTR 480P on pause.




Basically anyone can build one of these. My advice is to make sure your monitor is HDCP enabled (DVI-D input) and will work with a HDMI to DVI-D conversion cable. This will let you hook up any DVD\Blu-ray player with an HDMI output to it easily enough. My monitor is the 19" LG, no FCC issues.

http://ca.lge.com/en/products/model/detail...l196wtqbf.jhtml

Treat your LCD like a baby, if you get results as good as many of the others here, you will see any imperfections in the LCD on you wall when done. I've got a few small jaggy scratches that add now and then add 'character' to any scene.

Good luck to all and thanks to those that took the time to write plogs and help us all out!!

Cheers

Nice !
Perhaps a little more detail would be good though.
What are the dimensions of your completed unit?
Any ideas what sort of lumen you're getting at the screen?
Looks quiet, is it?

ps. This is in no way a criticism i think you've done a great job. I'm surprised no one has commented.
Well done.

Oh......I guess I shouldn't that razor blade around my LCD (ooooops) lol!
BTW, great build!


Oh......I guess I shouldn't have used that razor blade around my LCD (ooooops) lol!
BTW, great build!
(missed a couple of words)

The cabinet by LxWxH is 18"X18"x50" from the floor to top.

it is just big enough inside to take the full size of an uncut fresnel in case I want to re-use them in a future build. Since completion I have made a more permanent screen with stretched material over a frame. I added a matte black moulding for around the outside and it looks very good. I must say, it makes 100% difference having a properly sized and bordered screen to view, rather than a sheet of black out on a drapery rod hanging.

The final outside screen size is 86"X551/2" about 95" diagonal viewing area.



We have watched over 50 movies since completed in March of 2008. (We hardly watch any TV.) I also game on it frequently with the WII (ir sensor bar mounted at bottom of screen,) PS2 and Xbox. Mairo cart is great fun when 4 players each get the equivalent of a 42" TV to play on!! No problems to report so far. Rock solid when viewing blu ray material. Help from great people here has made all the difference. LUMENLAB ROCKS!!

Your results are beautiful... I am very surprised, . speechless

Did you AG strip that LG monitor or did it have the glossy type of screen not the flat matt type?

No AG strip. It had the matt finish on the front (side facing the lens)

Thank You...