Thanks for all the compliments and hope my write up will help some of you down the road. Honestly I've haven't been this excited over emulation since I first discovered MAME years ago. I think the biggest challenge I had was getting Visual Pinball and VPinMAME working. See this thread for reference (
http://www.hyperspin-fe.com/forum/showthread.php?t=7546) and I can't tell you how many week nights in a row where I found myself doing a fresh install of XP or Win7 at 1:30am. But thanks to the great members on the hyperspin/pin forums I got everything all worked out after a week. This is why I took the time to make all the screen shots in my initial posts to help you avoid the mistakes I made.
Now aside from software the cost of making one of these is a lot more then a standard 2 player MAME cabinet. Most of the cost lies in the screens depending how many you go with. Personally I would recommend going 3 for the best authentic experience.
You could get away with 2 and go with a 24" LCD and flip it sideways to have it display the back glass image and DMD. The problem in my eyes is the back glass image doesn't look right and stretched in the wrong way. Also by doing this you have a lot of extra space around the back glass image and will have to fill in that space with other artwork.
Another alternative should you use only 2 screens is not flip the back glass and just have the DMD overlap the back glass image. But again it won't look right or proper since it will overlap some important parts of the back glass image or they have some back glass images where it is shrunk vertically and a speaker grill gets put underneath it like this for you to place the DMD on.
Now for a 3 screen setup there is not only the additional cost of another screen but you will need another video card too. Now this second video card doesn't have to be the latest and greatest. I am personally running my old gaming BFG Nvidia 8800GT which is pure overkill but I couldn't be bothered to sell it on craigslist only to be low balled. Besides it works perfectly with my XFX Nvidia 250GTS card and same version of drivers. Now this is the next area of high cost are video card(s) and for the processor people have been using Intel or having the same success with X3 or X4 AMD's.
The rest of build is pretty easy especially if you get an old donor cab like mine which not only saved me time but money too. Before you start building your cab from scratch go price out some parts on
www.pinballlife.com. Check you local craigslist to see if someone is selling an older non functioning cab for under $200 complete with legs, stainless steel lockdown and side rails, playfield tempered glass and wood cabinet. The next challenge will be finding the right sized LCD to fit inside the cab and I really lucked out on mine so do some research on various sized and brands of LCDs de-cased on the Hyperpin or Visual Pinball forums.
If anyone has any questions about my build or the software feel free to post here or send me a message. Good luck and thanks for looking guys.