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    Building own 220v distribution panel (is this safe??)

    If your equipment is like mine ,then everything shouldnt go on anything larger than a 20 amp circuit. First get a sub panal and feed it with your 40 amp circuit coming from the main panal.That should break down your 240 to 120v. distribute your circuits from there.
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    electrical issue

    You say your running 2 1k lights per 20 amp?If thats true your oveloaded. 2000 watts divided by 120 volts = 16.6 amps, which right there is more than the standard 80% of the circuit(20 amps) So you are probably very close to trippin the 20s as well.Now Im a lil confused, first u say u have a...
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