My power switch is plastic and sticks out just a bit. I keep tape over it and usually run off an external wally battery. I don't really like those huge locking power switches. Just one more thing to snag in a pocket, etc. I'd go with the small plastic switch and ask Jerry to recess it flush. He should be able to shim the switch so it doesn't stick out at all.
Knobs next to xlr's is kinda crowded. With practice you can easily grab both knobs with two fingers. But you must be able to access the face at a certain angle to do that. A v3 shaped knob with flats would be nice because it would allow me to feel that the gain setting on both pots is the same in the dark (flats are aligned).
I think I prefer having everything on one face of the aerco. Putting controls on one side and i/o on the other makes the unit larger and could make control access more difficult in a pocket.
Be nice if Jerry could eliminate noise when changing gain but I can see how that might be impossible.
I don't think mini-xlr saves any room compared to xlr stubbies (except internally and I don't think you'll get a smaller box). But maybe you were going to do stubbie mini-xlrs?
RCA vs. minixlr.. Hmm.. Tough call. The xlr's I run are really tight so pull off is not a concern.
I imagine the +20dB transformer in the 20-70 model sounds different than the 0dB transformer in the 0-50 but I don't know... I don't think I could record dino jr in some locations with schoeps level sensitivity with a 20dB min pre. Extreme case, yes but I'm hitting them twice in june. Unless you want the potentially different sound of the +20 xformers, or need the 60 and 70 db gain, I'd go with the 0db model.
I'd definitely go with stepped gain. More reliable and quiet for the long haul. Also easier to set your gain at an exact level vs. "1:00", etc.
I like the idea of a single knob for gain. But I don't think I would have a balance pot into the signal path, even with a detent. Not sure if it is in the signal path or whether it modifies the amount of gain. Maybe Jerry would do jumpers on the board that bypass the balance pot? Though my guess is you'd always have it bypassed
As far as the clip light, I'd keep it simple. I already tape over enough LEDs on the 722.
Expect an MSMW MG210 > aerco vs. v3 comp later today!