Veggi... Sad to hear you are not doing well, hope you get better soon.

KNNA.. Each module will be about 15 watts. 12 modules total. No 660nms in the small modules, but I will be adding 2 strips 2.3 feet longstrips that will be 660nm. I will toss them in about a month before harvest.
My goal is to stay under average of 40 watt per square foot.

My primary goal is to replace a 500 watt CFL array that is used for Vegging only. If I can save 300 watts during the 6 week veg cycle, that will be a huge savings since they are running 18 hours a day.

To be honest I don't have high hopes of replacing my HPS during flowering. I am running about 50 watts per square foot for my HPS. So I will be comparing it against 40 watts per square foot LED. I think that is the best we can possibly hope for. I think the claims about 150 watt LED replacing 300 watt HPS are grossly optimistic. I have yet to see LED compete on a watt to watt basis against HPS. If I can get 40 watts LED to compete against 50 watts HPS during flowering, I will be overjoyed.

Heat sinks are extruded aluminum. I buy them from a guy on EBay who cuts larger slabs into any sizes you want. Very convenient and cheapest source I have found. I am going to try and run ducted area cooling over the top of the heat sinks, but have drilled holes to mount fans on top of each one if need be. Fans are little power hogs.

OldMac, Regarding your Red strips: Has anyone come out with a 660nm besides LED engin? Check out Luxeon K2s or the IIIs as opposed to Cree's.
They have a much wider bandwith and do a pretty fair job of delivering photon juice at 660nm. The Crees have a razor sharp bandwith around 620nm. I haven't had a chance to compare efficiencies, but imagine they are both very close.

In the past the LUXs have also been cheaper and available in better BINS. I have not worked with Crees, but from what I have read, the bare emitters are not supposed to be hand soldered. Given a choice, I will always work with an emitter instead of a star to eliminate an extra thermal barrier and save a few bucks.

I am now working on cutting the front panel to accomodate panel meters and switches. I also have to finish up two power strips with Cinch Jones plugs. The metal working is what really bogs me down, since I am working with basic tools. Lots of drilling, grinding, filing, tapping, cutting, blood,swearing etc.