A small package from the Netherlands arrived yesterday and I spent the evening putting the contents into chassis.
I used some chassis from CoZ Cables, which I have mixed feelings about. They fit together very well, all the holes are the right size and in the right place, there are just too many openings to suit me. Note that I've exchanged some email with Robert Cozart and I believe the next batch are going to be simplified. Robert was kind enough to offer me a new set of back plates but I declined, no reason to cut into his margins.
Anyway, assembling a pair of these as mono blocks is pretty easy. As stated in many other threads, this is not a complicated build. The important things are layout and cable dressing. This is discussed in the data sheets available from Hypex and that ship with the modules.
The only thing I found that causes me concern is not having a safety earth connection. They are designed to be Class 2 safety compliant and the SMPS600 module is supplied with insulated stand offs, though one is metal and meant to bond with the chassis to reduce EMI/RFI. Once I had the amplifiers assembled I decided to measure from line neutral to the chassis. It was 120VAC.
When wiring the PS module I followed the standard color code blue/white = neutral and brown/black = line. This made sense as the line fuse is on the brown wire of the board. Now the voltage I measured may be just leakage with no current but it does bother me. I tried reversing the leads and the neutral to chassis voltage drops to about 1.2VAC. I will almost certainly add a safety earth and hope it still sounds the same; I am exceedingly paranoid about safety.
Not much else to say. All the wiring is tightly twisted, 12GA wire was employed for the speakers with ring terminals on each end. The power wire is 16GA and I found some nice lighted switches at Radio Shack. I will likely build a soft latching power circuit at some point but the current setup works just fine. I connected them up last night and the result was as good as I hoped for.
A few photos.
Mostly built, switch and input not wired yet.
The gap above the IEC is because the cut out was for an IEC with switch module. None of the connectors on the bottom row are connected.