Well cd beam is building a 2W 635nm setup for his projector.
Good news is the beams come out in my setup around 4.5mm by 2mm. with a 0.85mRad.
So you dont need a pbs and a waveplate. you can just stack and get a 4.5x4mm beam
So 4 diodes each giving out 500mw gets you 2W.
So it is going to be one...