Designing my own PA

by circular you mean to hang the speaker vertically in clusters? could be cool but maybe trickier to get the angle at the audience right.

re: size of speakers i think youre right; ive always enjoyed playing through smaller type speakers (Nexos / Kling + Freitag / d+B each make an 8" 10" version of that) in spaces with less than 200 seats.
 
GM, I'll get on some sketchups. I'm fair with them but not quick. I have a CAD of the grid, and a CAD of the space, but haven't figured out how to merge them. I'll see what I can do.

Wishniak, they wouldn't always be circular. The space is just completely modular. Sometimes the seating is 360 with the stage in the middle, sometimes the seating is one-side only, sometimes two angled banks of seating, sometimes seats on three sides of a thrust stage. The goal is to have more, smaller cabinets that I can easily move/angle/aim depending on how the seats are set up. Right now I have four cabinets that are about 20' overhead, angled down, and hanging from swivel links so I can spin them to point at audience, but I can't adjust the pitch angle if the seating is closer/further away. I just point the horns near the middle and call it good.
 
What I prefer to do is A) DIY stuff so I can get more gear for my dough, B) invite volunteers in to help with the projects and give a mini Master Class (or amateur class as the case may be), C) I bloody love my job and this kind of stuff is fun, and D) biggest reason is my own learning. I would LOVE to know why the waveform of this horn is preferable to that one, or why this driver's T/S parameters will sound better in X cabinet instead of Y cabinet.
I understand all of these points. But there are some problems.
A) You don't get cheaper. Did you have a look what a professional plate amplifier costs? Good speaker drivers? And you still need some wood and a nice grill and ... You have to aim for top notch to save some money - but then it would be preferable you already pretty know what you do ;-)
E) Don't hang self built stuff over peoples heads. Even if it's not your fault, just someone doesn't hang it properly or whatever failed. If a speaker comes down, someone get's injured and YOU built the speaker ... don't do it in an professional environment.

For your speaker placements - bringing them up over the audience and "fire" directly to the people is a pretty good strategy. People will absorb a lot and you don't get a lot energy to the walls when the speaker have enough directivity (-> professional design with GOOD horn for the tweeter).
A line array would be needed to angled A LOT cause normally the first few cabinets are hanging straigth - these will blow the major acoustic energy right to your back wall. Seeing this a lot in halls - pretty bad results.
Get your Acoustic output to the seats and nowhere else.
 
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Already priced some plate amps at $35 for 70w. Darivers come in at about $29. Not professional by any means, but I use them all the time. And cheap enough that they can be replaced if they fail.... but none of mine have failed in 8 years... yet 🙂

I appreciate the disclaimer on the falling/killing. As I mentioned before, it is a non-issue.