OK, I am in the process of designing my projector around a 15.4" WUXGA panel using a slusher-type box. Since it's my first build I don't want to tackle folded designs just yet.

I wanted everything to be able to move, so the triplet will move, the LCD and fresnels will move, and the lamp/reflector will move. That presents a problem is when the LCD moves it makes the traditional slot in the top of the box useless, so another air intake solution is required. What I planned on doing is placing a slot underneath the LCD, a slot on top of the first fresnel frame, and a slot on the bottom of the second fresnel frame. Put a sheet metal shroud over each one to minimize the light bleed though, and have the intake port in the front and have the exhaust and fans in the back. Thoughts?

I have a Google Sketchup model here if anyone wants to take a look and give feedback.

It looks like you've decided to build an unsplit design.
If your lamp and triplet will be able to move, forward and back, then there's really no reason why your fresnels and LCD need to move. It's best to have the front compartment (forward of the LCD) sealed off from the rear compartment. This maintains the integrity of the cooling path, allowing cool air to enter between the LCD and fresnel, over or under the fresnel(s) and out the back. Any additional bends in the cooling path will reduce it's effectiveness. This could make your fans work harder and might make them louder.

Just something to consider.

Nice work on the Sketchup model!

I tried to make it pretty clear in your model. I just fixed a few things that I think may have given you some problems.

HERE IT IS

NOTE: I put three scenes in there to show you what I was talking about. When you download it, just click the three tabs at the top that are labeled and they will show what I fixed. Hope it helps!

That is so wicked, Windcalmer!
I need to find more time for stuff like that.

^^^Hey, I only started using Sketchup since I saw your stuff done in it. So thank you!

Whoa, awesome Sketchup work!!! (insert endless envy and worship here)

Thanks for the feedback, I'll go with the modified design. I plan to use 3 (possibly 4) 120mm Thermaltake fans Running on a fan controller. 2 would run at all times on a controller that adjusted speed, 2 would be off until needed, controlled by a fan controller.

I would like to keep noise to a minimum, thus running the fans at a low of an RPM as possible. Thanks for the cooling revision!!!!! See any other flaws with the cooling plan?

What lamp and ballast are you going to be using? Also are you going with a pre-con and reflector??? Just wanted to know so I could give oyu a more in depth opinion on your cooling setup. Cause I am running a 400 watt MH lamp with a pro reflector, and with two 120mm fans I keep the LCD below 80 degrees F. I had it set up for the election at the HQ here and with over 40 people in the room the LCD stayed at about 75 (I think) and peeked a few times around 78 ish.

So really anything over two fans is sorta overkill. Unless you want to do like you said an run more fans at a lower RPM to cut down on noise. ((Even with mine running wide open at all times, the noise is really not bad at all. Just FYI.))

I was planning on starting with a LL bulb and pro reflector. I plan on putting the ballast and an ATX power supply in a breakout box to keep the clutter inside the PJ to a minimum. Once I have a working box built I want to begin working on overdriving the lamp and building a drop-in lightbox with precon and hot mirror.

I was planning for cooling purposes to put in 3 fans now running at low RPM. When I build the lightbox I was planning on ducting 2 of the fans for a push/pull configuration through the lightbox and the third for pulling air over the LCD and through the rear of the PJ. Basically, I'm planning for further expansion and experimentation. I have also been researching the 1000 watt bulbs and thinking about heat considerations.

The light box is not really as important to cool. Yeah there is a point where things will get too hot. But the LCD should take priority.

Second, from everything I have read you really dont get much more out of a 1000W then you do out of a good 400W build.

Just two things to think about.