more AUX Busses

After all aux sends are used you can use either a group bus or a direct out.

Are you talking about your Ramsa WR-T820 or some other console?

I can't remember, but don't the channels have a direct ouput or an insert jack that can double as that? If so, there you go! Just patch the appropriate channels over to an external mixer and use that as your effects' sends. That would be pretty cool, because you can EQ, pans, etc. the sends as well as basic mixing.

OK, this gonna be gettin' a bit wierd here...
So I'm guessing that there are no direct outs on the Ramsa? Then you can use the Insert jacks to "tap" each channel out to a channel on the "effects station"...BUT you'll have to take that signal BACK to the Ramsa via the Insert's return circuit. This will require the appropriate patch cords to pull it off, plus the Mackie will have to be able to provide the proper level and load to get this done without a crapload of noise. Which Mackie do you have?
And you have to be careful about using the bus outs on the Ramsa, then feeding the effects unit (or the Mackie), then returning it back to the Ramsa. You don't want to create a nasty feedback loop by routing the signal out a bus, to the effects, and then back to a channel routed to the same bus.
What you might try is taking the 8 bus outs to the Mackie, patching the effects to that mixer, then routing the Mackie's stereo (or 4-bus) outs back to the Ramsa, using "open" channels routed to the Ramsa's stereo mix bus (NOT the 8 buses, or else the dreaded feedback loop!)...
Is your head pounding yet? LOL!!!

Moon,

I'm with you on going out the Buses, but I don't at that point see any purpose having a Mackie in the chain. He should just go out of a bus (or two) directly into the FX unit. There's input gain at the FX unit, so no problem there; and as you said, return it into an open pair of channels.
The only problem I can foresee is that the buses follow the channel faders, so moving those faders will change the gain at the bus(es).
Anyone know whether or not the Ramsa's direct outs are pre or post (or switchable)?

I think using the inserts will be far more of a pain (a patchbay would make it easier, but then he's gotta throw more money at the thing), and it will be more time consuming at routing time.

If that's the case then fader moves will not affect the recording levels, so you can run out of the buses without worrying about it.

The effects did not print to the recording

Did you want them to?

You got it, man, anytime!

Well, there are some good points here.
Olne of the problems is that there are several ways to route the signal during the trackin and mixing stages. I hesitated to push the bus method because I figured J was using those to track (and sometimes mix) with. That's how I used to use my analog 8-bus boards. Different strokes...
But if you are just going out directly from the channels to track, and you're not using the subs to track or "stem" your mixdowns, then, by all means have at 'em. That would keep you from dealing with another mixer altogether.
BUT if you ARE planning on using the 8 subs to track from, say when you are doing a live multi-instrument take to less tracks than you have mics...
The Direct outs from the channels can go to the line ins on the Smackie.
Then you'd use the Smackie to mix/route the various inputs to whatever effects you wanted to, then return them to that and route the outs from the Smackie to a couple of inputs on the Ramsa. Come to think of it, you could still use the Mackie as a giant effects return mixer even if you're doing the bus method, and mix all of the various effects to either the dedicated return section on the Ramsa, or to a couple of open channels on it. A myriad of possibilities,eh?
Now MY head is pounding!!!

Yep, there are many ways to skin a cat.

You could definitely do a sub mix from your inserts, or the direct outs, into the 1604. Get an RCA to 1/4" snake and have at it.

Both the directs and the inserts are rca, so you'll need a bunch of rca 'y' cables if you are also going direct into a DAW.

It would be a good idea, whether you're gonna go mobile or not, to invest in a few patchbays while you're at it. Half-normalled will alleviate the need for 'y' cables, but you'll need to get quite a few snakes (or a lot of three conductor and a punch tool if you're so inclined)...

Lucky you, I thought you said both the direct outs and inserts were RCA.

A punch tool: some patchbays (such as ADC) require a punch tool to wire them up.
Disney's full of these suckers.

Example: