The guys and I have been kicking around a few ideas to help our electronics go on a diet (20 lb plus electronics panel/s last year) and I've got a few thoughts (translation: probably illiegal)
Idea One: mount all electronics on composite board carbon fiber or fiber glass (yes I know CF conducts electricity), tap the composite and use nylon hardware This is very expensive, but one of our sponsors does composite work and we can have the scraps
Idea Two: mount all electronics on a massive printed circuit board. Design the entire thing in CAD. Route traces to he componants and then solder wires to the board to connect to the component. Also, build in any custom curcuitry and current sensors IN TO the electronics panel. In addition, get solder in fuse holders and eliminate the fuse block. Even better, get board to board connectors, make the entire thing modular and stack the boards. Simple replacement of any component. BUT, it might be considered using the chassis to conduct electricity, wich is agienst the rules
Just thoughts...
-Andy