gandhalf3 said:
hello, nothing is grounded yet, because the chassis is not there.
gandhalf, STOP. Do not pass go, do not collect $200. Do not turn on the unit again.
Disconnect your AC line.
THE SYSTEM MUST BE GROUNDED.
You have everything floating. This is dangerous - to You and the PCB.
Hopefully you have not damaged anything. Your mains ground, PCB ground, and XLR Pin 1's need to be tied together whether it's in a chassis or not. You probably have all kinds of voltage potentials going on. Not surprised it sounds like a shotgun when those relays switch. You'll probably have some sort of little click when the bypass is engaged as it's the nature of 8 sets of relay contacts closing, but it shouldn't be be loud, nasty, or bursting at all. The other relays you mentioned aren't switching audio, which is why you're not hearing them pop - but they're probably not happy right now either.
Most likely your electrolytic capacitors are probably all sitting there charged up because the charge has nowhere to go. With the unit turned off, check all 5 of your voltage rails, if they're not reading less than 1V, then you need to bleed them out - connect something like a 1M (highest wattage you have) resistor between the PCB ground and mains ground and let it sit for a little bit. Just to be on the safe side, use insulated pliers, don't touch the resistor with your hands (I'm paranoid like that). Of course in order for this to work you'll need to reattach your AC cord so that the PCB ground has a path to your earth ground. I would hook the resistor up first and then plug in the AC line.
Check your voltage rails with a multimeter, make sure they're not charged up.
WITH YOUR AC LINE CORD DISCONNECTED - Tie your IEC ground, PSU ground, and xlr pin 1's all together - you can just run a wire from each point and temporarily connect them with a wire nut or solder them all together - whatever you have to do.
Just please be careful. If you're not clear on what needs to be done please let me know, I can help you via AIM, etc.