jCOSbrew, thanks again for the inspiration on the little Bud Enclosures Nema 4x box. After having a mechanical engineer friend mock up my box using a 3D autocad program we found a way to make everything work even with my more complicated design; I had very little room for error but with the 3D CAD drawing to prove that it could work in an acceptable layout I went for it.
We then created templates using MS word that we then printed out and taped to each side of the box to perfectly align all the holes -drilled out the center of each hole using a small pilot bit. (It's pretty simple really; use the built-in Drawing tool to make boxes where the corners represent where you want the center of a component's hole -then label each corner for good measure.
Pictures of mine almost finished: http://www.facebook.com/photo.php?fbid=10151424325391929&set=a.10151336290 566929.536472.776771928&type=3&theater
(Bought the wrong size alarm buzzer, still need to organize my wire, and need a replacement nut from Auber for one of the yellow LED indicator lights but beyond that, good-to-go!).
-I ended up going with a 30amp design that will support switching between each of my 5500w elements (HLT and kettle); I didn't have a solution that I trusted for switching the PID controller's temp probe between two probes so I'll be manually switching the RTD temp sensor when I switch my heat output between the HLT and Kettle; they're identical temp probes and are identical length; I'll also only be using PID mode for the HLT so I shouldn't have any issues with throwing the temp probe calibration off.