Still cant find the URL i mentioned i couldnt find earlier. The jist of it was:
bulb -> <torn-open-cheap-lcd-panel> -> fresnel lens -> some other lens.
He was filling a very large screen from a good distance (15-20' away) with good brightness (room lights out, of course). For a cab, you're likely doing a rear-projection thing, and would need an appropriate screen to project onto from behind (all conjecture).
Fans are certainly needed to deal with heat, and I don't recall any mechanism to deal with overheating, but I bet it could be built that way (temp sensor -> pwr control). Since it's all a home-built solution, swapping bulbs should be easy. Not sure what they cost, nor their lifetime, but how many hours would a cab be running? If you consider how cheaply a low res 15" lcd panel can be had for, then add a bulb, lens, whatever.... again, not sure overall cost, but you'd have a large screen and maybe a fun project to boot.
Perhaps this doesn't really answer your questions. In the end, I guess it's more for the adventure than anything. The time and effort are likely to outweight any minor savings (if there are any) -- unless one is experienced, can do it fast, and save serious $$
Doesn't solve the LCD gun issue, however.