"Connector-less" Bulkheads: I was delighted to find that 1/4" o.d. copper pipe was just big enough to slide over the outside of the RG-141 coax. Using a sharp carpet knife, a small section (~ 1") of the coax jacket is removed, being careful not to damage the coax shield.  A piece of copper pipe (slightly shorter than the bare coax section) is slid over, and crimped at either end, to achieve physical contact between the copper pipe and coax shield

   "Connector-less" Bulkheads (cont'd):  After crimping the copper pipe, the dressed coax jumper is inserted in the 1/4" hole in the printed circuit board wall.  The copper pipe is soldered to the wall (on both sides).  Then, while everything is still heated, be sure to also solder the coax braid to the pipe at either end.  Heat shrink can then be slid over each crimp to tidy things up. 

Module Layout Planning -  The top half of the enclosure would consist of "full depth" modules, while the bottom modules would be shallower, with a front compartment running the full width of the enclosure.   Slight offsets between the top and bottom walls would permit proper internal routing of coax interconnections. 

Detail of Centre plate, to which all the boards will be mounted

Installation of module lids:  3/8" wide strips of the double-sided pcb were soldered around the perimiter of each module, making a lip to which the module lid would be attached.  (During soldering, courigated cardboard, cut to the same size as each lid) was used  to assure that the lid would be slightly inset from the top of the enclosure).  After drilling holes for the lid mounting hardware, STAINLESS STEEL screws were temporarily used, to permit soldering the brass mounting nuts on the underside of the lip.

This method worked surprisingly well!  

Building the boards, assembling off-board components, and planning the enclosure were parallel activities !!

Actual size photocopies of the boards (clearly showing physical location of each connector) were affixed to the centreplate during the planning and cable interconnection phase.

"Manhattan" Feed-Through Capacitor assembly - A hole with the diameter of small ferrite bead is drilled in wall.   Two 1" square wafers of thin double sided pcb are crazy-glued to each side of the wall (use the drill bit to assure proper alignment of the holes, while crazy-gluing).   The bead is then inserted, and a resistor lead run through the centre of the bead and soldered to each outside wafer.  Solder a small piece of copper foil over each egress point, and  solder appropriate disc ceramic capacitors from each plate to the wall.

Coax-to-board terminations:  After stripping back the end of the coax jacket, a piece of coax centre conductor (from one of the trimmed scraps of coax) is shoved under the braid.  A copper ring (from the 1/4" o.d. pipe) is then slid over, crimped, and soldered. This yields two "prongs", which are correctly spaced for the holes on the Kanga boards.       

Bottom half of the enclosure (Bottom View)

Bottom half of the enclosure (Top View)

This project definitely takes over your whole shack!

Ready for Final enclosure assembly:  With all coax interconnections, stand-offs, lid-mounting lips, etc. prepared, the time has come to solder the top and bottom halves to the centre plate.  I sure hope I haven't forgotten anything, because access to the innards of each module will become more difficult once the complete enclosure is assembled.

Function testing the time base generator

VHF Band Pass filter module.  Three glass piston capacitors are mounted to rail at top of photo.