I’ll update this thread with the final project costs as I posted previously, but first I’ll include a final review the project. Most importantly, the project is DONE and this is my resultant Large DJ Rack System...
I now have a two-piece rack. All of the critical audio components are mounted in the top rack. Only an Eliminator light controller and 3U drawer are in the bottom rack. The top can be used alone if desired, and it's very similar to my Small System in many ways, but the Large System has more built-in redundancy, and a nice additional mixer, through which all audio is funneled, including a separate channel for each of the four wireless microphones.
Here's what's NOW in my reworked Large System:
Upper Rack (SKB R-104):
Topside...
1. Denon MC6000MK2 Controller
2. Sennheiser Microphone on Gooseneck Stand
3. Gooseneck LED Lamp
4. Dual 22" Acer Monitors
5. Logitech Wireless Keyboard and Trackball Mouse
Frontside...
6. GTD Audio B-33 Wireless Microphone System
7. Denon DN-410X 10 Channel Mixer
8. DJ (Music) Nano Computer
9. Video/Light Nano Computer
10. D-Link 5 Port Ethernet Switch
Backside...
11. ART T8 8-channel Hum Eliminator/Isolation Rack
12. Rack mounted Power Strip
Inside...
13. MyDMX 2.0 DMX Dongle
14. IMP Line Level Combine
Lower Rack (SKB R-1406):
Frontside...
15. Eliminator ETPro-8 Light Controller
16. 3U Aluminum Rack Drawer
Backside...
17. Rack mounted Power Strip
Most of the components are the same as they were in my previous Large System, but the major change was going from a one piece (14U) rack to a split rack system consisting of two SKB molded plastic racks. Many of the internal components were also in the previous Large System rack. Here’s a list of what didn’t change…
1. Sennheiser Microphone on Gooseneck Stand
2. Gooseneck LED Lamp
3. Dual 22" Acer Monitors
4. GTD Audio B-33 Wireless Microphone System
5. Denon DN-410X 10 Channel Mixer
6. D-Link 5 Port Ethernet Switch
7. ART T8 8-channel Hum Eliminator/Isolation Rack
8. MyDMX 2.0 DMX Dongle
9. IMP Line Level Combine
10. Eliminator ETPro-8 Light Controller
And here’s a list of the new components…
1. Denon MC6000MK2 Controller
2. DJ (Music) Nano Computer
3. Video/Light Nano Computer
4. Logitech Wireless Keyboard and Trackball Mouse
5. 3U Aluminum Rack Drawer
6. Two Rack mounted Power Strips
Obviously the next biggest change was going to a rack-mounted Denon MC6000MK2 from my original American Audio VMS 4.1, which sat in its case atop a small table with the 14U rack rolled underneath. The new system does not require a table. Another pretty significant change was replacing the two rack-mounted computers with two smaller and lighter Nano computers. I saved a lot of weight and space (and noise) with these new computers, but gave up some performance
So the BIG question would be: did it meet the original objectives? Here's what I was trying to achieve...
1. Downsize if possible (smaller and lighter). I need to be able to lift it in and out of the minivan.
2. It needs to be quicker to setup. Must take less than an hour to set up, and tear down needs to be reduced.
3. It needs to be durable.
4. Needs to retain as much contingency/backup capability as possible.
My budget was $2,000.
I think I achieved ALL of the goals (at least to some degree), but the budget???... OK, I busted the budget. The final cost of the project was $3,385.70 (not including tax or shipping). The Controller, Computers, Power Strips, and Racks cost a total of $1,590.60. Where did the remaining $1,800 go???... Well except for a few other components, it went to paint and building materials, cables and connectors. This project kinda nickel-and-dimed me to death. There were items purchased that didn’t work out; cables and connectors that did not get used (this time).
My goals were pretty simple, but there was a lot of scope creep. The height requirement was not originally factored in. It wasn't until I stood at my controller after mounting it in the slant-top rack that I realized I would never be comfortable working with it at that height. Making the height extension module (I named it the High Heels) was a necessity, and it afforded the opportunity to include the facade.
Adding the Facade was a BIG addition... in more ways than one. The (necessary) elimination of my 30x30" adjustable height table meant the table cloth/runner I used to hide the rear of my rack (and the exposed cables) was no longer viable. Something different was needed to hide the cables. I'd been thinking about making a facade for some time, but didn't want one like all the four panel folding facades you see all the time. I built a folding facade with three 15"x36" panels that unfold into a 36" wide by 45" tall panel that attaches to the back of my rack, allowing it to move as the rack is moved... I call it a Floating Facade. It was not something I was planning to do in the beginning, but it's now one of the features I like best…
Final cost to build the Floating Façade… $573.95.
There was some pretty clever engineering that went into the making of this system in terms of the modularity of the internal systems, the structural supports, and the brackets and mounts… most of which had to be hand crafted due to the sculpted and asymmetrical nature of the SKB racks. The sliding antenna /Floating Façade attachment drawer, though a bit kludgy, actually works quite well, and the bottom slider built into the High Heels works great. The durability of this system is as-of-yet an unknown. Time will tell.
Ultimately, I’m pretty satisfied with this version of my Large System. There are a few things I could have done better, but the final result will serve me well… until I decide to do something else. I’m pretty sure this will be my LAST traditional rack system… not because I think racks are passé, but because I think I can design and build something that will work better for me than a rack. We’ll see.
Thanks to all who contributed with suggestions and comments. Your input was always given thoughtful consideration, and many of your recommendations were incorporated into the final system. This is my last post in this thread unless there are questions or comments.