On Monday I cut the aluminum plates for the front / back to size. I used a circular saw, which was terrifying (my brain was screaming 'why are you trying to cut metal with this!?!?'), but it worked out fine. Next step is to cut the holes (most will be done with a drill, but there are some sections which will require non-circular cutouts, which I will attempt to do with my scroll saw). I have done this before on a smaller piece, and it worked out fine... here's to hoping that these larger cuts will work too.

Yesterday I screwed the switch mode supplies into the footprint. I am using a scrap of particle board for the base of the enclosure, and all the components, including the front and rear aluminum plates, will attach directly to this. The cover will be of 1/4" hardwood, and will be mostly cosmetic (although it will help to channel the fan's airflow towards the appropriate components).

Here we have the current plan for the enclosure, as seen from the front / rear / top. (The rear is still lacking a bit of detail; it will have the AC code plug and a fuse).

Finally I have a couple pictures showing how the actual layout is progressing:

The next step is to cut the front faceplate, attach it to the base, and get one channel wired up, so that I can start doing some real testing on the channel + controller. (It is hard to test when high current wires are just hanging loose on the bench...)

Cheers