Mosaic:
Just saw the 5mm oval that you found, very nice. On average looks to be 25% brighter than the 4mm, with slightly narrower optics. The binning of the lower power Cree led's leave a lot to be desired, with the rated luminosity values spread over a very large range.
Sounds like an interesting venture - being the developer of the original program I'll lend a hand with any software questions I see someone already got back to you about the SF User Module Pack..