I seem to have got to the bottom of this. My rather large purchase of the rear projection screen looks to have been a mistake

the screen material appears to filter so much of the IR light - that I can't use it for rear projection in this setup. I'm really annoyed - as you can imagine. I've been asking around and people have had success with thin cotton fabric and various other things like tracing paper on a window. Those are OK - but not great for me touring around at events with the setup! I have found a supplier of spandex/lycra screens in Canada - but I don't know if these will be ok for letting the IR light through
http://www.djscreen.com/index.phpHopefully once I get to the solution - it will help others who try to build a similar thing!