Yeah. After taking the better part of a year to collect the parts I have started to build. Just a little slow at updating this thread!
I have updated the wiring diagram (again). Just some slight changes with the main switch - instead of only controlling the BCS power supply it controls the main contactor providing power to the panel. Here is the updated pic:
I started with the panel first. I went with a Budd Industries NEMA 4x ABS enclosure. I chose this based on it being water-tight, easy to drill, and easy on the wallet. Dimensions are 19.7" x 15.7" - figured this would be plenty big with room for expansion (e.g.: valve control) later. As it turns out things will be pretty tight anyway! I mounted all the switches and LEDs on the door. The best thing for drilling this box was a step bit. Spade bits work too. I did need to use hole saws for some of the larger holes but the melting plastic and fumes probably took a few years off my life!
You can see the holes where the L6-30 receptacles will be going. The other 3 smaller holes are for the L5-15 outlets. These won't be flange outlets but regular round outlets fitted and sealed with silicone. I couldn't justify the price difference here. No hole for power IN yet - it is not totally ironed out yet and I want to make sure I use the right size gland (not springing for a NEMA connector..).
I started mounting things in the box. Contactors are 40A with 120V coil (Ebay), Eurostyle terminal blocks, 3AG fuse holders, 4-relay board for the pumps and HLT stirrer (Ebay). The heatsinks (40A external from Auberins) are mounted on the top with the SSRs attached:
I've mounted a few more things since taking the pics: XLR connectors for temp probes and a pass through panel mount RJ45 connector. These come in near the BCS. Oh, and the outlets for elements and pumps at the bottom are in place.
I think that's it. Now I have some wiring to do