Your thread is one of the things that got me thinking that someone could help me out! A lot of similarities.
To answer your questions:
1. The beams are pretty good. Here are some pics (below). I'm pretty sure the last pic is earlier but with these same three diodes but with the original fixed dichros and mirrors.. I couldn't get the near field and far field alignment right, which is why I wanted to switch to a better dichro mounts and a bounce mirror for the red (thank Buffo for that suggestion). Also that red is crappy after the bounce mirror because it's right on the edge of the mirror.
2. I know, several people told me that!! I wanted this to be a good small general purpose projector.. the scanners in there now are OK up to about 15k, but choppy after that. Are the x-lasers even worse? What would you suggest as an alternative that would also fit inside the box? If it's just a good beam projector and a not-so-great graphics, I'm ok with that too. I have two other projectors which are good at graphics.
3. I figured I'd cross that bridge once the hardware is put together if that's either dialing down the flexmods or in Beyond. But IIRC, the output of each RGB is "just about right". I'm not a perfectionist by far, I just want to finish this box and play with it. Take it to friends' houses since it's a pretty compact form factor. That kind of thing.


