Help me solve the issues keeping my projector from primetime

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Finally after investing countless weekends I'm nearing completion of my projector. There are still a few issues which must be solved and I hope you veterans would be able to help me out.

1) Fan holes - Right now I have an inlet fan and outlet fan postioned on opposite sides of my box next to the light. I only have grilles on them, but no filters or vents - huge amounts of light come out of the box. I have no idea what to use or how to successfully block out light. What types of ductwork work best? I was thinking of going to Lowes and getting 10 feet of aluminum used on roofing and cutting my own as well as lining the inside of my box to help with heat reflection.

2) I have a solid partition mounting my 8x10 piece of lexan. The heat from the lamp is affecting it, causing it to bow. This intern transfers to my condenser fresnel. Also I have mounted my ballast in the front of my box. I had no idea the electronic ones got so warm, looks like I need more fan holes.

3) There is dirt everywhere in my box. I tried cleaning the fresnels with lens paper, but I can't get into the grooves. There was a lot of missteps in the project, my fresnels have taken a beating. Washing them didn't help - water spots formed, I used a camera lens cloth but it didn't do any good. Is there a way to clean them?

after I get that sorted out I just need a good screen yet. I really need to get this project taken care of, watched hitchhikers guide to the galaxy tonight, looked pretty decent although the amount of light in the room really detracts from the image.
 
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