hey sir woody, nice results there!
there is also this thought that crosses my mind. we always measure the beam at apperture, like, after the last cyl lens. however, this beam has a spot, around 40-50cm away from the diode where the dot is actually round (where the fast axis and the slow axis have the same spot size, due to the one diverging much faster than the other etc etc etc).
It is not so difficult to arrange inside the projector so that this point of the beam (is it the beam waist?) is the point that hits the galvo mirrors. this should allow for a smaller apperture and no clipping from an otherwise fat beam
does this seem like a go?
"its called character briggs..."