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Sorry for the terrible necrobump, however, I may have something to add about the problem with the stray beam.
It may be the result of the tube (tunnel aperture) you use as the clipping aperture.
I was playing around with a 1mW keychain and a bit of tube the other day, and found that reflections from within the tube can get collimated into the beam, especially if the clipping aperture is placed before a lens.
Check for reflections within the aperture or damage to the faces of the prism pair.
The best way to clip a beam is to build a 1:1 beam expander, and have a pinhole aperture at the focal point. Slowly move the pinhole aperture from the focal point until you get the desired result.
Yes, you'll lose a fair bit of power, but it'll probably end up cutting out the stray beam in the process.
It may be the result of the tube (tunnel aperture) you use as the clipping aperture.
I was playing around with a 1mW keychain and a bit of tube the other day, and found that reflections from within the tube can get collimated into the beam, especially if the clipping aperture is placed before a lens.
Check for reflections within the aperture or damage to the faces of the prism pair.
The best way to clip a beam is to build a 1:1 beam expander, and have a pinhole aperture at the focal point. Slowly move the pinhole aperture from the focal point until you get the desired result.
Yes, you'll lose a fair bit of power, but it'll probably end up cutting out the stray beam in the process.