Well the 2nd stripdown went well for me. I went with a method hinted at by Gadgetsmith, the do-not-disconnect-the-2-FFC's method.

Sry for the length, i strove for overly detailed rather than "you figure it out."
sidenote***: my current 520D that i've just received is different than my original 520D (as shown in Forkev's stripdown)... the 2 FFC's are narrower and actually have the hinge doors at BOTH ends (heh, 4 X the possibility of breaking one, YAY!

). The control panel FFC also can disconnect at either end (cant remember if thats how the original one was). And there is a alternate mfg name on the main processor rather than Pixelwork (dont know what that will mean as far as its performance... i couldnt make out the name last nite but will see if i can come up w/ it later. or if anyone else has seen it you might post for the curious).
** you will probably want to have your LCD frame ready prior to this, but not necessary. - i went w/ the alum frame + dremmeled plastic backframe method as many have used, no silicone needed. - then mounted this to some wood.
-No pics yet, as i'm waiting until completion to gather up my images and do a plog/pjgallery-
i'll be borrowing from images in
Forkev's CMV-520D stripdown (since i'm lacking mine currently) if using this method there are obvious differences in the stripdown... would be nice if someone could do another stripdown describing/visualizing techniques of how to go about this method, i would but i'm UNWILLING to reassemble disassemble my current working LCD all framed up in its disassembled and working glory. Yes, seeing that upside down, reversed image from your stripped LCD is one of those "high" points of the DIY LCD Projector process.
Basically you would follow his strip down until STEP 12 in which you should take special note (and mark it draw it out if necessary) of where that one screw mounting goes to the underlying ciruit board for later positioning purposes. Continue to step 14 where you are instructed to disconnect the 2 FFC's between the strip connector and the main circuit board
BUT DONT.
Though from an earlier step, look at this image:
Forkev image 1on the metal backplate (right side of pic) you see the circuitry housing with the control panel FFC going out the right to the CP (in the pic). Disconnect the control panel FFC - choose which end seems easiest to you, one end has a hinge door but is easily accessible, i found the other end to be slightly cumbersome to get "back in the hole" due to the adhesive on one side sticking to your fingers as you attempted to "gitRdone."
The aluminum Circuitry Housing AND tin underneath the circuit board is what we're after and the realy sexy part to all of this. Rather than disonnect the 2 FFC's you can remove the aluminum CB housing ( one screw-->KEEP<-- and simple clips that you slide it out of- but be gentle and constantly watchout for the strip connectors and those 2 main ffc's).
With your Circuitry exposed you'll want to unmount it from the tin (several screws-- KEEP the screws).
Forkev image 2Now comes the somewhat "scary" part as it can feel awkward. I also had the aid of 2 other people and recommend at least an extra couple of steady hands to help you out-- as you read you might think "thats crazy" and you'll definitely think it if you try it; i'll just denote that its quite possible to do and we pulled it off without a hitch, just must be steady, calm, and again will probably need at least one extra pair of hand if not more to hold things in the air as you or whoever works.
Your circuitry is unscrewed, screws kept tidily nearby. You will want something like towels (preferably lint free), or some small cardboard pieces and papertowels to place in between the LCD and the circuitry boards when you get to this point (another reason why a couple extra people are handy - when you get to "this point" you will probably have fragile items in your own hands.
Have a "bedding" of whatever you choose already laying on the table, this is where you'll lay the emancipated LCD (seran wrap might be nice to lay on the towel to help keep the LCD clean and free of annoying dust). you'll still need "filler" materials too as they'll have to sit on top of the lcd with the circuit boards on top of other towels/cardboard .. whatever.
OK, you or someone else needs to lift up the circuit boards carefully, making sure to support the middle area where there is a small power bridge that connects the 2 boards (i believe this *might* be able to disconnect safely- i chose not to... if someone knows for sure, please post). Obviously the person holding the CB's is STILL connected via the 2 FFC and must be acknowledging them at all times- making sure not to stress them. Next someone needs to free the LCD from the metal backplate & plastic while the other someone holds the circuit boards in the air. This part is cumbersome and kind of scary since everything is supported by human hands, (i remember it being very silent and tense like we were in surgery) but be calm and gitRdone. Once you free the lcd, lay it on your bedding and get the filler materials laid on top of the lcd so you can then finally set everything down. WHEW!

Next, take the tin backplate and rip the backlights out (ok, you dont have to RIP them out other uses for them found
HERE.)
Once you have just the tin backplate you want to use some cutters or dremmel etc to cut around where the aluminum CB housing sat, basically the area around the screw studs AND the lil clips for the alum housing. The idea is to cut that section out and you'll be able to remount the CB to it and the alum housing and have a PERFECT little CB housing (perfect since its what it was in to begin with- no messing with making a new mounting that will fit.. you already have one!) See the bend in the metal under the CP ffc ?
forkev pic 3you may want to cut that as well as part of a sidewall as this could stick up in your light path (depending on how high your LCD frame mount is).
You should see how you can now mount the CB back to the tin backplate you've cut out to nicely fit your box and then you can mount the alum CB housing back on as well for a perfect little cage.