I stayed up late last night working on this for hours with my girlfriend. Actually I had to hold the lens in place while she used her thin fingers to gently wipe off the image chip inside the lens assembly, and the mirror. My fingers are too fat and "sausagey" (LOL) for such delicate work!
I didn't get a chance to test it before bed because the projector didn't turn on!! I guess I missed a wire somewhere, I hope it ain't busted but it was unwatchable. We cleaned the opticals again and again with both a wet nap and a microfiber cloth, then more air, then more wiping, repeated until all optical surfaces didn't have anything on them. It should be ok now, if I didn't ruin the electronics during all this jigging around.
Replacing the lens itself is more a question of finding the right way to mount a new one to the existing enclosure, while being able to keep it sealed shut after you screw it all back together. I recommend doing this at the same time as the cleaning job because if you get extra dust in there, you can fix it before putting it all back together. I think my own dust blobs came in when I had a screw in the top out, which left a tiny hole and allowed some air in. Because blowing air through the DMD tunnel thingy shouldn't arrive inside the "sealed" (I use that term loosely, it obviously isn't perfectly sealed) assembly, because there is a lens on both the input and the output of this assembly, and they are both snugly fit. The air and dust blobs for me while cleaning it must have come in from somewhere else.
Anyway, the blower fan should also be replaceable, if you can find something that doesn't take up *any* more volume (because it fits snug between some heat sinks at the base of the case, there really is no wiggle room there for something larger) or with much larger, variable fan rate quiet-spec blower fan that you install outside the case and have it blow into it some how, probably a tube. Quite possibly the best mod for this case is a blower fan that you jury rig into it somewhere else, like possibly where one of the other fans lives. Then you still have to make sure enough air is getting out of the case. Quite possibly, the best, best solution is a flat-style blower fan, that you drill a hole into the base of the case and tape its hose well into the input of the other one.
I'm not doing ordering any new optics or fans until I get my PJ back to working 100% (heck, at this point, even turning on LOL). Hopefully tonight.
It would be GREAT to have a quiet projector. I heard that a lot of manufacturers also have DisplayPort 1.2a scalers with Freesync, so I may look into trying to get one of those and haxx0r this little projector to have a DisplayPort input. Another thing I thought about to get 1080p 120hz 3D for 3DTV Play, is to follow NVidia's way to get get 60hz 4K over HDMI 1.4 : use 4:2:0 chroma subsampling. For fast-paced games and movies, it would be great to have full 1080p, up to 60hz per eye 3D, with variable refresh rate.
If I ever get that working, maybe using some of those Blu-ray lasers to mod this projector into a retrofit laser projector would be super cool too, because you could have the light travel over a fiber optics into the projector, thereby removing the need for any fans in there aside from the already-quiet heatsink fans (which I'm sure could also be replaced by even quieter ones).