Having just joined up I wanted to let people in on my first real DIY projector (as opposed to the last 2)

My previous work with "DIY" projectors has avoided the illumination end of things and focused on optics and software. I have been using a combination of CRT projection lenses and 5" LCDs to make my previous attempted projectors. While mucking around at work with optics (I'm a Ph.D. physicist working on 3D displays amongst other things) I had occasion to work with some surplus CRT projection lenses. While looking for specs and other material I encountered the DIY projector scene. Having bought a few lenses for home and having found some Zenith 5" TFT screens on closeout I decided to make a DIY PJ.

My initial work involved simply placing the backlit LCD in contact with a large CRT projection lens (Anchor Optics #B35890) which produced spectacular but dim results. I then went to tweaking gamma and making a blackout cloth screen. Unhappy with the limitations of the composite-in feed of the Zenith, I got a PSone LCD and did a VGA mod on it. This brought the resolution up to a tenable level but the image (using only the backlight) was still dim.

This leads to my first real projector, a weird but interesting design which should prove interesting:
I'm using the following:
PSone LCD with VGA and Brightness mods (leaving AG on for the moment)
8.5" fl Fresnel lens
Lamina Ceramics BL-3000 (525 Lumen) LED array cool white (dense pack) with 60 degree spread lenslet array.
Lubic Extruded Aluminium framework
5" CRT Lens

My light engine is up and running with the big 5.5" dia 1" thick heatsink getting slightly warm (i.e. I can feel some warmth when I touch it). No IR no UV
The 8.5" fresnel does a tenable job of collimation (within the limits of the diffuse source)

Hoping to mount up the LCD and the lens in the next few days.

I know that the ligh levels will be low and the diffuse source will effect the image, but I am attempting to compensate with the CRT lens (built to image a lambertian source in contact) and the relatively close position of the led array.

Can't wait to see your results! I'm doing a very similar PJ, except that I'm planning to build my own LED array. What was the cost of that BL-3000 array with the lenslet setup? I might still abandon my plan to build my own if your results come out OK and the cost isn't prohibitive.

Good luck!

The LED array is about $92, the heat sink about $25, the lenslet array $5 from digikey
The part numers are:
521-1014-ND 91.38000 $91.38
521-1016-ND 25.62000 $25.62
521-1020-ND 5.14000 $5.14
The driver (buckpuck 3021-D-E-1000) is about $20 from ledsupply
The Power supply for the driver (AC->DC 30V 1A) is $9 from Jameco

Probably the same as making a cluster but...

The BL-3000 is insanely dense with insanely bright elements. Check out the website for details:
laminaceramics.com/products/bl3000.aspx
They pack 39 superbright LEDs onto a large postage stamp!

Links not going through for me.

This link is fixed

thanks I was a little scrambled on the link
should have a first test tonight!

first ligt
no images yet have to wait for the ffc extension for that
screen door is bright but has hot spot with cut off have to recheck my fresnels