Thanks for the kind words, albaron. You can find a lot more details (and tons of help and advice) over on Lumenlab. Here is the link for the PLOG (projector log) for that particular project:
http://www.lumenlab.com/forums/index.ph ... ntry2129551. The lamp depicted in the picture is a 150W Sylvania Metalarc bulb (HSI-T 150W/NDL). I later went with a GE Constant Color 150w ceramic (CMH150/T/UV/U/942/G12).
2. Sounds like you may have answered your own question, but yes I technically used 4 lenses total. The fresnels and the triplet (projection lens) are required. The precondenser helped me harness more light and shorten the distance from lamp to rear fresnel.
3. See the plog linked above for more assembly pictures.
4. The box is kinda heavy, to be honest. About 40 lbs. But your could certainly choose a lighter material than white pine.
FWIW, I got out of the DIY projector game a while back. I sold all the parts in my (then) current project and only needed to kick in about $100 more to get a 720p commercial projector that destroys anything I could come up with.