One of the things I noticed with my HD500 is how vulnerable the power, L6 and USB connectors are to damage.  In tight quarters I was always having to be extrememly careful where I stepped for fear I would break one of them off.  I read all the stories about the USB jack breaking with too much force.  I also can't understand why they would not have put a simple ON/OFF switch instead of making us disconnect the connector or the wall wart every time.

Anyways, I had made a pedal board before to use my Flextone II floorboard with my Zoom G9tt and it worked pretty good so I decided to try it with the HD500 and it is a good fit.  I had to open up the back panel for clear access to all the outputs but that was easy.  I hard wired a 12 ft extension cord in place and recovered it with some nice vinyl immitation tolex from Parts Express and it works great.  All the connectors stay hooked up and are hidden inside the box, safely out of harms way.  The space where the old floorboard sat is usable for any pedals or gear you want to put in the FX loop and it keeps a nice tight footprint. 

All in all less than 20 bucks at Home Depot and some left over parts.  I may hard wire an ON/OFF footswitch in the upper left corner when I can find a good one and I am looking for good ways to secure the cords to prevent trip damage.  Check out the PDF and comments are welcome.