Yeah, I use the clipped corners a lot on my 8x10 (whoever sanded the focussing screen at least clipped the corners properly), probably because the lenses I've got are a lot tighter in coverage. On 4x5 I know that I run out of movements before my SWD runs out of coverage, so I never bother with the corners much.
I was also thinking about using a film-holder and just sliding it under the GG, but I'd have to hack up an old one I don't have, it'd work fine sliding 8x10s under the rail but for smaller I'd need glass or something, and if I'm going to build something I may as well get it all milled in one go anyway.
Meanwhile, I just ran some quick numbers. The cheapest and brightest LED at Element14 is
this one, a 5mm through-hole. If I assign a 6x6mm space for each, I get a grid of 41x33=1353 pieces covering 8x10 (I'll probably need a few more around the edges for evenness, and could get more in if I spaced them hexagon-style, but it's good for a ballpark).
With all of them, I get 62,373 Candelas of light, consume 86.6W, and just the LEDs cost $392 (and I have to solder and cut 2706 leads). I'll have to get rid of all that heat too, probably a lot of thermal vias and a heatsink clamped to the PCB (I also know people with $30k Pro-Eng Finite Element Analysis software to calculate that, thankfully).
Of course, that's just the most I can fit in, I may not need all that light so I might be able to get something cheaper or use less and space them out more.