I've moved away from thinking about using lenses as they restrict the
footprint size. If I double stack the LEDs then a spacing of centres
about 8.5mm is possible and so 14 LEDs in a 32mm diameter. So can be
quite close to the light tunnel and 20 degree beam spread is fine and
outer LEDs approach angle will still only be 30 degrees or so, and a
reasonable proportion of that will reflect only a few times and
substantially get to the DLP chip. Will still try 5 LEDs initially.
Will power up individually at only 100mA or so and set the angles of
each individual LED for maximum brightness at a simulated window with a
photodiode , then wire all in series and make a more substantial back
mount before transfering to the projector