I'm working on building an electric HERMS setup (inspired by The Pol), and am going to document it in this thread.
I'm only deviating from The Pol's setup a bit... I'm going to use a PID/SSR for heating the HLT to give me more flexibility in wattage of the HLT element. Also, I occasionally brew at friends houses, and want a rig I can fit in the back of my Ford Explorer, which will include GFCI protection on the rig itself. I will be able to plug in to a 20amp 120v circuit at a friends house and use a 1500w 120v element and should have enough power. When I'm at home I can put in a 2000w element if I want faster heating.
Here is my preliminary 'ghetto fabulous' wood cart design. 4' wide, 2' deep, 2' 6" tall. Conceived in Google Sketchup:
$10 worth of lumber, $2 worth of deck screws, and $6 for 2 rigid casters and about an hour of assembly time and my creation springs to life:
I'm using wood for now mainly because of budget constraints, and wanting to try things for a while before committing to a metal stand.
I'm going to put some plywood/masonite on the top and bottom for surfaces, and cut a hole for the element wiring in the HLT. I still need to purchase a HLT stir motor and paddle, a march pump, and I'm going to make the HLT coil. I've got pretty much everything else purchased. Will update this thread as I progress.
Thanks to all of the info from HBT members, and especially The Pol. It has been very helpful.