jostenmeat - No fat faces or distortion. I know the projector should be at least as big as I suggest as I check the projector calc. at Projector Central.
Their calc is a rough guide, and is known to be inaccurate at the extremes. It's to get a ballpark idea of where the sweetspot should be. Unless things have changed (I doubt it), you are advised to stay away from the extremes if you want the best PQ, it doesn't matter which extreme. I don't understand the mechanical or physical reasons behind this advice, but this is what I have read regarding all the techs of PJ, LCD, LCOS, DLP, etc.
Also, the manual says 100" from 9'11" (full zoom) to 11'6" (no zoom). I am at full zoom and 12' to attain a 105" screen. Yes zoom is limited with DLP it is only a 1-1.15x zoom.
I'm not the brightest crayon in the box, so tell me if I'm wrong here: Those numbers don't quite add up (??), and you're trying to push the max angle by more than 2/3 of a degree, compared to the full zoom max number you're giving me.
I would like to exhaust all ideas before I move the projector mount back.
I would not consider that all ideas are exhausted until you contact the mftr. I have contacted the mftr's of enough of my AV items that I have lost count. They include mftrs for my processor, cdp, bdp I think, definitely UPS, amplifier, and this is just off the top of my head. Oh yeah, speakers too, and more than one brand there.