I have received some much appreciated design help from Runar Borge, and thanks to him the board is now fully redesigned to fit inside a standard cartridge housing. We've also discarded the atrocious bluetooth module and focused on USB instead, using V-USB.

3 new boards (rev 1.0 RC1) were ordered today at OSHPark, and a new post will be added once the first board is soldered up and ready for action!