What sort of size rooms are you using this in?
I'm taking my smaller projectors to a job tomorrow in a room that holds about 300 or so people.
The red is enough for that space, with an even but not heavy haze.
So I wonder why your 500mW red isn't cutting it (in your perception)?
Is there a lot of ambient light?
I had some custom modules made, combined red/blue, single diode of each, with prisms and correction optics, and I can tell you that they were not much more per module than buying a 1W 532 OEM-VSYou're kidding. It's like 3 times as expensive. Buying off the shelf anyway.
That said, I also spent nearly £2k on a 1W 638nm Kvant 6 diode array module when they were brand new. Lovely, but for the effect, you don't see that it's so many times more pricey.