Building mixer; can I have some pointers?

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Hi, all- I'm new to this forum 🙂

I'm trying to build a fair-sized mixing console based on a Mackie 32-8 mixer, but tailored to my needs. I have simulated (on the computer) my circuits and they all work, but some questions I have are: what is signal and earth grounds? Do I connect them both to the earth terminal on the power supply? and do I build the case out of metal and use the case as the signal ground or do I build the case out of acrylic plastic and then use a signal ground bus?
 
For best performance, signal ground and earth should be kept largely separate, connected at just a single point. (Search the forums for "star grounding" and "ground loops" to see why this matters)

You want a metal case for shielding purposes, and this must be earthed for electrical safety.

So, to sum up: All signal grounds should be connected to a single point, or at least a nice heavy bus bar. The case should be connected to the earth terminal of your power supply. A single wire should also connect the signal ground to the earth terminal.

Also, read: Earthing (Grounding) Your Hi-Fi - Tricks and Techniques
 
Your cost for parts will be 2 to 4 times the price of a brand new unit. For an inexperienced mixer builder, the odds of yours working as well as a store bought unit are slim. Start with something much small and get all your routing problems worked out.
 
I have built a prototype already that works perfectly. The prototype featured eight input channels with phantom, two pan-equipped submasters, and a stereo master bus. I currently use it now with my eight principal drum mics but will reuse the parts for building the big mixer.

I don't want to buy a store bought mixer because none of the analog mixers I've seen have all the features I would like. the Yamaha PM5000 has enough inputs, but is a live console with no tape returns and is EXPENSIVE. A Mackie 24-8 has tape returns and is affordable, but it features only switchable auxes, pre/post-fade sends are selected in pairs, and an incomplete EQ section. I figure that spending the money on building my own mixer would be worth getting all the features I need
 
I'd build a mixer just for the fun of the experiment if I could afford the parts and time, so I say go for it!

(In the real world, I'd lash out for a Midas Verona. Not that it necessarily meets your requirements, but it's by far my favourite analogue mixer to use. When it comes time to layout the panel of your mixer, I'd look there [and certainly not at the Mackie] for inspiration)
 
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