I have been working on my pj for a while now, but am just now starting my PLOG.
I am doing a mix between a Haas style pj and a Joe's bakery PJ. I only really have one piece of innovation that seems different from everyone else's, and I will post that as I go. Tonight I fired up the light and aligned my lenses. Hopefully this will be done within a few days. I will post some pics that I have been taking when I get a chance. My pj consists of:

Benq fp591
Mix of Haas style and Joe's bakey enclosure made from aspen
HTPC 2800 amd sempron
LL lenses and triplet
Evercool PCAC fan - sound about equal to a PC fan
Ushio bulb
LL e-ballast
Lexan XL10
12v dc converter

Well, I finally finished, besides some tweaking, screen building, and plugging of light leakage. I will post my pictures of the build soon, and some of the image when I have something to project on.

I do have a question. I used formica for the top of mine like that done in the Haas style pj's, however, the formica above the bulb seems to get very hot, almost too hot to touch. I am not sure if I should be worried about this or not. You can actually see an orange tint when the bulb is on at this area of the formica. If anyone has a similar build, please let me know how yours reacts. My LCD temp was about 85 degrees after around 20 minutes, but that back area was very hot. Maybe I should make some sort of heat sink, I do not know. I currently have flashing covering my wires only. Thanks for any help!

i would add flashing around the whole light section, stand it off the sides, top and bottom a min. of 1/8" for air pocket.

Good Luck, but im sure it will turn out awesome!

Well, I added the reflector, and put flashing in most areas from the back to about 3/4 of the way through the bulb. Now I have formica that is too hot from in front of the bulb to the Lexan. I am not sure if anyone else that has light from the bulb hitting the formica has the same problem with heating the formica, or if I am the only one.

The picture looks pretty good now. Sealing the light leaks and decreasing my size to about 120" seem to have given an acceptable brightness, but not fantastic. Hopefully my HTPC wil lbe able to help from this point.

I did not get that "wow" increase in brightness from my reflector. I am not sure if it did anything really. Most of the improvement seemed to come from plugging the light leakage. Maybe it is not really installed correctly, but I didn't really see much difference when I moved it back and forth during testing either. I will post pics soon of the build and image.

I learned the hardway. My light was focusing ~1/2" above center of the triplet. I actually moved the light down 1/2" inch but come to find out I could have moved the front fresnel up 1/2". Not sure if that will help at all but it increased my brightness quite a bit.

Well, everytime I think I am done, I find that I have to do something else. After approx 1 hour of watching "Hero", the pj hit 97 degrees. I am currently using one evercool PCAC fan, and fear that I will have to add another. I am growing frustrated with this, but the picture looks pretty good, although it could stand to be a bit brighter.

I will add some pics when I get a chance of the build and images.