Hello Claudio and Group,
After some more thought, I think we should pursue TO-220 devices. Putting the heat on the board and then taking it off is just too complicated. The RD06HHF1 is the obvious choice, but expensive. Alternatives are the IRF510, STF2N80K5, STF5N60M2 and FQPF3N25, all in TO-220F. The TO-220F package has an insulated tab, and can be bolted directly to the case. The thermal resistance is 4 to 6 degrees per watt, well within our heat budget. I no longer think the TO-220 will be a problem mechanically. We can mount it directly at the OPA2677 on the under side of the main board with holes to access the screws. To mount it, we slide in the board and mark the case at the screw holes. Then we drill the case, place the TO-220's under the board, slide the board in, screw down the TO-220's, and then solder the three leads. To remove the board, we unscrew the TO-220's and slide the board out. If it does not slide easily, we heat all three leads at once with a soldering iron and pull up on the middle lead which we have left a bit long. Removing the board and then reinstalling it with heat sink compound is a bother, but not that difficult. We would test the HL main board completely before installing the TO-220's. All other amplifier parts including relays and filters will be on the top surface at the front, and so can be assembled and changed without removing the board.
I looked at a two board design, but two boards are more expensive than one, and raise the problems of interconnection and excessive distance between the OPA2677 and the sensitive MOSFET gates. If we use Steve's 4004H-6N 10x15 cm box, and if the HL main board can fit into 10x10 cm, then we have 5X10 cm for the power amp, filters and relays. That should be enough for a few bands. Just like SoftRock, the user will build the bands she wants. So there it is, a complete ready-to-go QRP rig on one board. We need a BNC antenna jack at the back. We need to route the RF power and DC amp power carefully. Since we have four layers, we can use stripline instead of microstrip; or mini coax. We can leave off a strip of the solder mask between the HL main board and filters to solder down a shield.
For more bands we need a second board and a taller box, such as the 4006H-6N or 4012H-6N. The TO-220's must stay where they are, close to the OPA2677, so that the distance to the MOSFET gates is minimized. We add a second 10x15 cm board in a slot above the first board. To interconnect the two boards, we design the main board with a row of through-hole pads for IO along one edge. These match up with an identical row on the second board, and are wired together with jumpers. Connecting RF is more complicated, but we now have single ended 50 ohm RF, so we can use mini coax. Again, all parts on the second board are on the top and can be assembled and changed without removing or separating the boards. I think this should provide enough space for John's amp and filters.
The design is not ideal for those who want to use HL without the amp. They are stuck with a 10x15 board instead of a 10x10 board. But they have the extra 5 cm of space and a blank front panel that may be useful. It also requires a more expensive second-tier PC board instead of the cheaper 10x10 board. But at least it is just one board. I am also assuming that the OPA2677 directly connected to MOSFET gates is a good design, but that has not been proven.
Jim
N2ADR