CP,
About your recording setup. Does the mixer have channel inserts or direct outs? You can use those to feed your HD24 recorder in lieu of the sub outs. If you use the inserts, you just have to be careful that you only go to the first click as you plug in the cable. It is an unbalanced signal, but that's not much of a problem in most cases. Direct outs are typically balanced. I've found that I'm going direct to the recorder from my outboard preamps nowadays more often than through the board unless I have lots of channels to record simultaneously.
Anyway, when I got to your stage in my control room, I installed an insulated steel exterior door with the pre-hung jam and seals. It works well except for the bottom where I have the majority of my sound leakage. I guess I need to install a bottom stop with a seal to close up that spot, but I don't want to have to step over it, so I've been reluctant to do that.
Anyway, have fun. Sounds like you're getting close to the finish line.
Darryl.....