Rigs and other equipment
For now a couple of photos of my 2 metre project. As you can see, it's a linear amplifier, based on designs by Jim Klitzing, W6PQL. This version is capable of 1 kilowatt, but (apart from dummy load testing) it won't be used at that level, partly due to the UK power limit of 400 watts, but mostly that if it's under-run it will probably never fail.
The case was designed using the free to use software Front Panel Design which is available to download from Schaeffer AG in Germany or from Front Panel Express in the USA. The software has a steep learning curve, but once you learn its ways, it's an extremely accurate and powerful tool. Templates are available for most components and they're especially useful for things like 'N' type sockets, where a mounting hole is required that has two flat sides. Occasionally a template is not available and it's quite easy to modify and store an existing template or just design your own. Once you have your design accurately defined, you can either make your own panels, or you can submit them back to the company, who will make your panels for you and they will even apply finishing paintwork, including powder coatings.
Although having your panels made for you is a bit expensive for a one-off production, it can actually prove cheaper than having to buy or hire suitable tools and spraying equipment to make your own, especially if you desire a highly professional looking end result.
To fix all of the panels together, I've used small metal blocks which have pre-drilled and threaded holes in each plane. The blocks are called "Gewindeblock M3" and they're available from Funkamateur via their shop in Germany. To preserve bonding continuity around the entire casing, I've scraped away any paint back to bare metal where each block touches a panel.
The heatsink and RF deck were obtained from W6PQL who also supplied the bare control board. It is possible to make your own deck but it's actually economically more viable to order it ready made from Jim, along with the components to construct the control board. Other components were sourced from suppliers such as Mouser, Farnell and RS Online, with some hardware found on eBay.