Update on the SMT board:
The design of the PCB is done and is now roughly 2.75" (6.99 cm) x 1.09" (2.78 cm) and that's where its going to stay. This is down from the original board's dimensions of 3.81" x 2.50" or a 68% reduction in footprint, even with additional circuitry. The parts are on order. I'll check for fit and order up the minimum quantity of PCBs.

Stu
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If you want it to break, buy Sony!