Thanks all for the comments!
I the dicros are not from the projector. Yea, hindsight is always 20/20 for future versions I will change the layout to maximize red output. Remember Prototypes.
DjHeadie: wow smaller, cool. I could not think of any way to make it smaller without getting into custom beam combining optics. I would love to see what you are working on. Half of the size is from the drivers. Without removing the to-220s and smashing the drivers together It came out this size. It is 1.9"w X 1.9 tall by 4"L, 5"L if you include the mounting ears.
chad
When the going gets weird, the weird turn pro.