Sweeper, just finished reading this thread thru again today, but have been following it for quite a while. Have you considered, after you've finally got it completed to your satisfaction, to possibly document it with a parts/materials list? If it's been as inspiring to others as it has been to me (and there seems to be a number of us out there following it), then maybe it will allow us to follow in your footsteps, while avoiding some of the struggles you have ran into. Also, if you have some time down the road, could you possibly put down a quick/condensed version of your build, nothing too elaborate, seeing as you will have a Lot less time to play (for a while, at least) as soon as the new addition has arrived. This though you will find is a good thing, just a big change in priorities. (I have 2, so I know of whilst I speak)

The main things I would be interested to know would be a general run through of your design/planning process, the parts you chose and why, things to look out for while putting it together, and any changes you would have made if you had the chance to do it all over again. By this I mean even after the tear out/rebuild you just did, anything else you'd of changed if you could? Bigger (!) case, diff materials, etc? Oh, and maybe things to look out for during the build/testing process. No rush, not at all, but if you could post something short, maybe a page or so, that would be huge to the rest of us mere mortals if we were crazy enough to think about trying to do something like this. I say crazy because I would venture a guess that most of us don't have the set of skills you obviously posess (so it would be that much harder for most of us), but with you having blazed the trail, it would help make up for our limitations.