New PassDIY Headphone Amp (now available)

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how did you cut the rectangular hole in aluminum for power entry module?

I drill four holes on corners and use mini dremel with flexible shaft to cut the rest between corners. Leave some space to the required size and finish with the flat file. Aluminium is easy to work with.

One might also drill many holes one next to the other and finish with flat file. Tedious, manual work, but the final result is the same.
 
If you have 18V between positive and 0V and negative and 0V, then it is most likely some sought of wiring issue.
Did you follow Wayne's earlier suggestion on how to wire up it up using capacitor etc?

Edit: I can't remember if the amp is using 18V regulators, so my first comment relies totally on that being correct.
 
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