I put together another projector with the down-tuned 400mW "Analogo" laser ebay module I reviewed a ways back. Everything in this build was purchased off ebay!
The size of the unit is roughly 8x8x4.25"
The case was machined by me using my mini mill. I used an older end mill and didn't use mist coolant which I feel negatively impacted the results but hey, I learned something from that experience. The letter engraving was done using a diamond drag bit.
Other details:
-LaserShark driver (mounted on a piece of laser-cut acrylic)
-Ebay no-name allegedly 30K galvos (they are a tad out of tune which gives this projector... character. I still need to track down the manual for these. The power supply that came with the galvo set is HUGE. It takes up about 1/4th of the space in the projector.
-12V 3A ebay switching power supply
-2x 15x60mm fans (27cfm) mounted to a laser-cut acrylic air barrier.
-Aluminum for the custom machined handle
-Plasti-dip for the handle (I would have gone with the spray stuff next time for a more uniform finish.
-2x2" BK7 window
-2x safety handles (you have to push them in to turn and re-adjust the handle/mount/foot.
I used high temperature flat black grill paint to paint the non-annodized parts.
This will be my largest build size-wise. I am going to try and push the envelope on how small I can get the next one which will likely involve quite a few custom optical, electrical, and mechanical parts. It's probably going to be a while. The next one will be direct-drive analog too.