If anyone out there knows where I can purchase a new light tunnel, or has an old broken in any condition 4805, x1 or x2 they would like to sell I would be more than greatful to buy, as I am desperately in need of parts for my one.
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Sounds like Light Tunnel Failure. Very common. Biggest problem is that a replacement part is almost non-existent and a manufacturer repair is expensive.
You can get further details on the problem at www.avsforum.com. Just search for "4805 Light Tunnel" and you will find threads about DIY repairs.
I also recently posted a DIY Replacement thread for anyone willing to make their own tunnel: www.avsforum.com/avs-vb/showthread.php?t=1304694
It sounds like you have mounted the replacement light tunnel incorrectly. It is a common error. What has happened is you have the light tunnel sitting on yop of the positioning stop which is opposite from the color wheel side. If you take it back apart you will see that it's not laying parallel to the casting. if you reposition it so it is just touching where the opening is in the clamp on the color wheel side you will feel it fall into place.
You will see once you've taken out the light tunnel ( also known as the packlight pipe module ) that there is one or two of the small mirrors that has come loose as a result of the lamp's heat.
Glue them back with Super Glue that dries very fast.
Do them one by one , always try to build them back in from edge to edge i.e. - If the top one and left side one is loose , do the side one first and then the top one - just makes it easier.
Remember you only have one shot at this , so do it carefully.
It also depends what part you need because although the 3 models look similar none of the parts are compatabile with each other except maybe some body parts and the X1 and X2 share the same light tunnel but it would be a risk to assume that the light tunnel from a used model is OK. The only 2 models that share the same parts are the X1 and SP4800. The X2 is brighter and the SP4805 has a 16:9 native ratio.
This is definetly the light tunnel issue. After searching and a million phonecalls, I tracked down a place that you can buy the light tunel for $41 on their own and simply put that in, making the projector good as new. I Have the phone number of the place and also the link to the forum giving you fully pictured diagrams of how to change the light tunnel, and also I have a service manual if anyone would like it to be sent to them.