Jazz. Obviously I am listening. I am reading every word 5 times!
Obviously I am working within a budget, but I want to do things safely, and I admit I no electronics engineer, so i am asking for help...

I still can't understand the need for additional breakers or fuses in the box when the chassis power connectors have fuses built in.

On my last machine i had the E-stop wired to my BOB, however i was using a router which had it's own on / off switch. The VFD seems to of complicated everything massively.
So i would appreciate you telling me how i could wire a safe E-Stop.

Chatting to that chap about his cramped case, he said he had 2 48V fans which keep everything cool and it had all been running fine for 2 years plus.
I was thinking i would do the same.

None of you are saying i would have an EMI issue, rather more a heat issue which should be able to be controlled with fans, should it not.
Thanks again.
Martin