Brad,
I agree with tribble, but I also looked back at your comparison of the DPPS green projector with the diode green projector in your last pair of images. The "too tall" 520 is actually closer to the 445 in beam size. but because the 445 is much less visible the weak halo in the first image is missed and the line "looks" tighter, but it hardly is. Also notice in your very first image in your first post. The red is your tightest beam and this is (in my experience) the most divergent beam. I think Omar needs to focus the blue better as well. Finally, measuring off the screen and making the assumption that any blooming by the camera is not too different for the three colors, I measure the blue at aprox 2.5 mrad and the red at 1.5mrad. What did Omar specify the divergence of the projector to be?