I decided to go with AAHMEGA60. The board is about to be sent off for production in a few secs and I'll have some protos to load in about 2 weeks. I'm only about 90% happy with the layout but as I'm just doing it in the little spare time I'm happy enough.
Below is a rough preview of what the board will look like
Prototype boards just turned up. I've got a bit of free time while waiting for parts for another job to turn up so I'll start loading a board or 2. A couple of the parts needed for the AAHMEGA60 are still a week away so it'll be next week before i can power it for the 1st time.
I know that you said it was a bit much for a kit but other than the SMDs it doesn't look that bad. Have you thought about installing the SMD components and kitting the rest? Just a thought.
There's about 120 SMD components which makes up almost everything except the 60 mosfets and the connectors. Without fully assembling the boards there is no way for me to test them or to install the firmware. The original firmware will need to be installed via the ICSP programming header but all public release firmware will be via downloads that can be installed via a thumbdrive.