First the good news, then the onto the fun.
HDMI cables arrived (my almost two year old intitially wore them as a belt and declared them pretty). I brought the PS3 down and went PS3 via HDMI to Yamaha V661 receiver to Moome ISS HDMI card in switcher to PJ. Everything went good, which was a relief since multiple HDMI connections can create snafu's, especially with a boutique product like a moome card which ads HDMI to older technology.
Dropped in my only SACD, Dark Side of the Moon (figured I'd try them out since the PS3 can play it), and had music while I monkeyed around with the PJ. The machine is not level. But its not as bad as I was thinking. I deleted all the old input memories and it made things better. Here is convergence at the begining of the night in an old input memory.
Here it is in the new block, after I midpointed all the settings. Its a bit better.
If you display a red-only image it doesn't look too bad:
But in realitly, it still sucks (both images from transformers trailer on PS3):
I am leaning towards taking it down and redoing the unistrut. Do you think one person of okay, but nothing great strength can handle taking down the PJ alone? I'd remove the lenses to lessen the load. I can wait for help on Monday, but it compresses time if I need to take it down, redo the strut and rehang in one evening while my friend is there. I am debating whether to take it down so I can do the rebuild on Saturday at a more liesurely pace, then my friend just has to help me heave it back up.