Hmm, not that much, really. But I am very, very, very paranoid until all the protection systems are in place--variacing things up, watching on a Flir, checking output volts/waveforms before anything's connected, etc. There's a prototype in CC right now that has a big sign on it:
Don't plug in prized headphones! May blow them up! Not kidding! And that just doesn't have the protection systems running, it's perfectly listenable if you're careful. The big speaker power amps are the scariest, but even those have been pretty mild. Sorry to disappoint.
But, if you want to get into building, here's how you can avoid a lot of pain:
1. Treat any new device as if it's a bomb and might blow up until proven wrong.
2. Get a variac (a device to vary the AC line from 0 to full voltage) and use it religiously. On everything. Even wall-wart powered products.
3. Get a Flir (infrared thermal camera) and watch the board as you variac it up slowly. If something lights up like the sun, confirm it's within the range of typical operating temperatures...unless you're running tubes, or big power resistors, anything over about 60 degrees C should be looked at. It's either a fault, or you need to bring the operating point down a bit.
4. When it's up and running and not running too hot/smoking/etc, run it through the modes, especially low gain (typically higher feedback) to see if anything goes bonkers. "Goes bonkers" means smoking parts, bright LEDs, bright like sun on Flir.
5. Check output for lots of DC. Fix if lots of DC.
6. Check basic I/O (does it output a sine wave if you input a sine wave, is the square wave relatively free from overshoot, etc. You can do this on an inexpensive scope, some even have signal generators built in.
7. If it passes all those tests, make sure volume works (and turns DOWN), turn it down, and then maybe have a listen.
Remember all of the above are very crude tests, just to get you to something that's kinda-sorta working without smoke. There's still tons of work to do to get to something you want to use everyday.
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