Lot's of good ideas here, thanks. Sorry to say but going for bigger rack is no go. I started with deep 4U ATA rack that had plenty of space. Rack itself weighted 12kg but was bullet proof. Generally deep racks are bulky to handle and now I wanted as small as possible. Think rack but super compact trying to compete small bass amp in pelican hand luggage type case. Darkglass amp is the only solution making things really easier, but 1200€ price keeps me out of it.
This is exactly what I was thinking too. In gigging, simple and practical is the way to go. I was so happy earlier with simple RBI + power amp, but now I cannot go without Darkglass (grown out from Sansamp). It is something I must tolerate in the signal chain.
If you're gigging a lot, I'd shoot for whatever is most simple and straight to the point while giving a tone that is at least usable if not exactly what you want. I've found myself going into forays of wanting to try different stuff, more complex chain, etc, but always returning to the most stripped down rig possible to not have to fiddle with a bunch of stuff. I do cart around two heads in case one goes down (like you mention), but one of them is a markbass nano so in essence weighs nothing and takes up almost no space in the bag. But all of this with the caveat that I don't know what kind of music you play which may require more than a stripped down chain.
This is exactly what I was thinking too. In gigging, simple and practical is the way to go. I was so happy earlier with simple RBI + power amp, but now I cannot go without Darkglass (grown out from Sansamp). It is something I must tolerate in the signal chain.

