Well, after months of work, several prototypes and a near divorce experienceI have finally half finished "Big Red". Now he's looking presentable I have persuaded him to model for a couple of pics.
He is currently sporting 8 Opnext HL6545MG diodes running at 230mA per diode and at 5.04v produces 1300mW with a 3mm beam and under 1.6mrad divergence, and he loves Robin Bowden's Die4Drive drivers (thanks for all your help Robin)
He is only half finished. Opposite his current array he'll be getting another 8 diodes and will end up pushing almost double that out of the business end. More pictures to follow as he evolves.
Beam spot pic @ 27m:
Inside:
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