Head-up display (And how to fixate stuff with 1/10 mm precision)

You know, this forum has ALOT of experienced members. But if you won't tell us what the #^@% you're trying to use this setup for, none of us is going to be able to give you an accurate answer. All we need to know is WHAT you are taking a photo of with it, so we can understand exactly what you're trying to do here.
 
It's quite simple to arrange for an image of a display to be superimposed over the main image by using the setup you suggest. Believe it or not, this has been done with instrumentation many times before - especially in the days before electronic imaging. The semi-mirror doesn't have to be at 45 degrees - you may be able to flatten the angle a little. Fixing split focus is a trivial matter. The timing is a different matter, and a little more detail of exactly what you want would help.
 

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