For anyone still following along here, I figured I'd include another quick post with some more details and observations.
#1 - With a setup such as this one you will obviously be in for a lot of guesswork and trial-and-error. What I can relay is that I have been using Makerjuice SF. My initial prints such as the mickey mouse above were done with short layer cure timings of about 4 to 7 seconds. The prints do not seem to dry so I have begun adding to the cure time per layer significantly.
My current settings are about 21 seconds per layer with bottom layers at 23 seconds. Prints did seem much harder. I do not have any current photographs to share just yet. In part this is because of observation #2.
# 2- The choice of having everything as a separate component allows for more flexibility but also causes trouble for me to align everything each time. I have moved from the original test rig to a V2.0 which is much smaller and portable. Unfortunately, the Z-Axis is one item. There is a stand for the Vat, which is two and then my projector is item three, mounted on a tripod. Since all can be adjusted individually it proves challenging for me to set it all up and take it apart each time. Unfortunately I am a bit tight on space and can not set everything up once and leave it there.
Aligning the projector so there is no keystoning has been challenging. I would suggest that if you attempt any of this you should try and create a single structure instead of doing what I have done.
# 3 - UV lighting.
I have never seen any metrics out there which would allow people to compare what the strength of their projectors are. Something like that would actually be very useful to us all. Anyhow, I decided to purchase my own UV light meter. It is a model YK-34UV. In my tests it barely registered anything under normal room light conditions but did show about a 2.6 (on a 20mW/cm2 scale) when about 2.5 inches form my projector, where the build plate normally sits. My projector had been unmodified.
I have now removed the UV filter from within my projector. I tried testing once again and I believe the new numbers are somewhere between 3.x and 4.5 or so. My projector was on for about 15-16 minutes before it began to overheat and auto-shutdown (something I knew was a possibility but did not do anything about). I have purchased a small 12V PC fan which outputs 30cfm and hope that I can mount it to extract some added heat so the projector stays on without issue.
I will not have time to test this week but I will try to post once again once I have another opportunity.
Anyone who is interested may contact me and I can share some details about the direction I may be heading. I'm currently looking to switch to a more robust Arduino script and may also be considering new slicing and display software. I have also recently heard of some new options for light sources which may make life easier for the DIY users out there. More to come soon.