Rack Server - Conclusions

Looking back I learned several things. On this page I'll share with the world so that others can benefit from my experiences:

Buy the outer plexiglass after the frame is built and sized. Working in reverse order, while possible, complicates each inner step
19" racks are 19" on the inside. Mine is 17" on the inside between the wood parts. This kept me from using anything 19" mountable
A two step drill bit will fracture these plastic shelves. Use a dull bit - as it will heat its way through.
Small motherboards are much easier to fit space wise into a shelf.
When working on lower shelves, finish them before going to the next higher one. I neglected to attached the bottom shelf CD player until the end. Which meant I had to pull the shelf to work on it. Just extra work that wasn't necessary.
Wiring is important and should not be over looked: 5 PCs have 8 wires each -> 40 wires from the PCs to the quick connect, 40 wires from the connect to the LEDs, Switches on the front panel.
Switches on PCs are open circuits until the button is pressed, then its a closed circuit until the switch button is released.
LEDs with a cross over voltage of 2 volts will work in your PC

In all, this was a fun experience - which met most of my original goals.
Would I do it again? Yes -- but I would do things a bit differently. :D