Lizard King:

Your contact in Chicago was defintely on the right track. I have noticed most of the DIY cords are based on simlar principles: good hospital-grade connectors (such as Hubbel) and good, heavy gauge OFC copper cabling. The last thing that ssems to be common is the use of an EMI/RFI suppressor such as a ferrite barrel integrated at the source-end of cable.

Lastly, the hospital grade parts seem to be popular among tweakers, extending even to the receptacles themselves. Believe it or not, many people swear by the Hubbel hospital grade outlets for A/V gear.

Personally, I don't know if I'm interested in going quite that far.