Rick wrote:
Funny, we can't imagine these lenses AREN'T still made.
Sony told us they aren't, but we've been told by three
different repair shops that that's not true.

The repair shops may very well be correct. But I can fully understand
why they wouldn't be manufactured anymore. The average service life of
a rear projection TV manufactured in that era is probably somewhat less
than 15 years, especially without a MAJOR repair. You have either been
VERY fortunate with your set, or it doesn't get an excessive amount of
use. To me, it would make no economic sense for Sony itself (or anyone
else, for that matter), to continue making a specific replacement
screen for a specific model of TV 15 years old when probably 90% of
them are dead and gone. And the vast majority of folks with a 15 year
old set still operational wouldn't think it sensible to sink a SECOND
$300 into ANOTHER screen. But if the TV only sees intermitant use, then
perhaps your approach DOES make sense.

And while you've got it all apart, how about adding a protective
screen?

Good idea, although the outer frame is a friction fit and
doesn't allow for much additional depth in the lenses.
We might be able to add a very thin protective screen.

I'm not sure I understand the need to add a protective screen while the
TV is apart. My 5 year old Toshiba 61" has an aftermarket protective
screen that I added which is held on from the front of the frame with
velcro. It's about 3/16" thick, and cost me about $100, if I recall
correctly. I'm sure you could make one yourself for about 20 or 30
bucks.

Jeff