Just an update...
I finally got my fans, and have managed to leave the projector un-mounted and turned off the entire time so that I can start this fresh and keep it cool right from the start. What started as a simple project turned into something slighty more complex (don't they all??
I was originally just going to get a 12v plug-in wall transformer, put a switch on it and run it up to the fans which would mount behind the projector... but then, in the course of having a conversation with my fiance which went something like...
"Ok... now I'm going to be putting some fans up on the projector, and you can NEVER EVER forget to turn them on when you turn the projector on, since they block air when they're off."
"What happens if I forget?"
"At the very least, the bulb will blow out if it
gets too hot."
"Hmm. What happens if I remember to turn them on
and the bulb still blows out? Can't you do something
to make them both turn on at once?"
<insert bad 70's action movie music here>
So what I decided to do is kill two birds with one stone. I picked some 3 conductor power cable, a plug, a female AC power connector, a multi-voltage transformer, a switch, a couple of electronic project boxes, some split loom, plexiglas, weatherstripping, Dremel bits, and a vast assortment of various things that could be used to rig up or make a mount for this thing.
What I ended up with is a new power cord with a heavy duty in-line switch, that runs up to a junction box mounted near the projector on the ceiling. The junction box contains the transformer and outputs 120VAC for the projector and 6-12VDC (switchable 6-9-12) for the fans.
I cut a piece of Plexiglas, including 3" cutouts to fit the fans, with 1/2" lip around the entire edge when the two fans are mounted side-by-side. The fans mount to the back of the plexiglas, drawing air out through it. On the front, I've got an edging of 3/8" thick x 1/2" wide weatherstripping (which forms a reasonably good seal around the projector to draw out as much air as possible).
As for the mounting, I took two straight brass friction lid supports (picture a tongue depressor with a groove cut down the center, mounted to a pivot at one end with an L-bracket) I mounted L-brackets to the back of the fan assembly giving a nice right-angle mount to attach to the lid supports. The other end of the lid support screws into the mounting board that the projector bracket mounts to, so that I can pivot the fans to adjust to the projector angle and then back out of the way again whenenver I want to un-mount it.
I don't know if it's going to help the lamp issue yet or not, but so far it's passed the fiance test... she thinks it's "Cool" and looks like it "Belongs There" (which is High Praise considering how much she cringes whenever I put some new electronic device in the den).
So now there isn't much else to do but wait and see what happens as I get some hours on this thing. Here's hoping I don't have to post about it blowing up again.
-Mike