Your budget. 
Seriously, caseworks and heatsinks alone will cost more than your cost limits. Add in a huge transformer, PSU caps, and then the components and PCB and you'll be looking at $250 minimum.
Then double this, as you're likely to blow it up a few times during construction if you've never worked with anything that high powered, the risk to yourself with the high voltage rails required, and then add another $250, (minimum) for the test equipment you realise that you need to get it working.
So, what can you do?
Buy a used PA amp - can be cheaper than you'd think.
Get some tried and tested Class D modules that you can just screw together and case up. Will cost more, but will give you the satisfaction of doing it yourself.
Start off building a 30W chip amp, then progress onto something using discreet components like a Symasym. Once that's up and running well, build a bigger amp, something like the new diyAudio class AB amp, at 150W you're getting there. Then start thinking about 600W...
Seriously, caseworks and heatsinks alone will cost more than your cost limits. Add in a huge transformer, PSU caps, and then the components and PCB and you'll be looking at $250 minimum.
Then double this, as you're likely to blow it up a few times during construction if you've never worked with anything that high powered, the risk to yourself with the high voltage rails required, and then add another $250, (minimum) for the test equipment you realise that you need to get it working.
So, what can you do?
Buy a used PA amp - can be cheaper than you'd think.
Get some tried and tested Class D modules that you can just screw together and case up. Will cost more, but will give you the satisfaction of doing it yourself.
Start off building a 30W chip amp, then progress onto something using discreet components like a Symasym. Once that's up and running well, build a bigger amp, something like the new diyAudio class AB amp, at 150W you're getting there. Then start thinking about 600W...
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