Guys,
I think Bob mentioned that it should be possible to make it as an internal version...
Just to clear things up...nope - not possible. There's no way this monster is going to fit inside our enclosures. The only way would be to do a multi-level board. Seeing the inductors are so big (tall), they would have to go on the innermost level, i.e., the board closest to the center of the enclosure and furthest away from the outer terminal plate. That would cause the greatest amount of weight to cantilever away from the support points on the terminal plate. One good jar and it would snap the screws and we'd have one big assembly laying at the bottom of the enclosure. And no...with the internal structures of the enclosure, there is no space to mount it in the bottom of the cabinet.
So...if you want this thing it's going to be an external assembly or not at all. In light of this, give me your input on what form you want it to take. I'm going to do one board layout and one assembly construction for all. I don't have time to re-invent the wheel for each individual. Well, I guess I do... but it will cost you. Time is money and this monstrous contraption is going to take enough of that as it is. Heck, it's going to be bigger than a lot of amplifiers!
In light of the above, do you want it in a box with a metal plate for the terminals covering it? In a box with a Plexiglas cover w/terminals mounted to it? On a nice hardwood board (5 species to choose from) with some type of plastic cover?
Talk about it amongst yourselves and hopefully you'll come to some consensus. Whatever the majority decides (if there is a majority) - that's what I'll build. The odd man out is going to pay more if I have to do something different just for him. If there is no majority, I'll take everybody's ideas under consideration and then build it the way I see fit. Please be advised that whatever form you pick will have a cost associated with it. We can make it a plain ol' black box or as pretty as you would like.
Please don't think me a jerk here. Doing a professional layout on something this big and complex is not a 5 minute job. To be done correctly, component path lengths must be as short and compact as possible, while considering EM interference from nearby components. Anybody can plunk some parts on a board and wire it all up. Ask any EE...board layout can completely make or break a design, regardless of the component quality. This sucker is going to be using the best parts in the world and consequently expensive - no matter what. I'm not about to compromise the design or fail to extract every last minutia of performance by being hasty or trying to cram everything into the smallest/cheapest box possible. I'd rather not do it at all then waste your money and my time.
I'll be standing by.
-Bob