Oh yeah, forgot to mention PCB selection from yesterday. I originally ordered 10 PCBs from two different board houses.

First supplier:

• Quality was "meh"
• The silkscreen wasn't sharp
• The soldermask was sloppy and dithered on the edges due to a rotational misalignment of the PCB with the printer axis.
• Top copper layer were damaged near the board edge when they routed.
• The copper fill between the pins of my SOIC 8 were removed (wtf? these are within spec)
• Drill hits were "ok"
• Ordered a stainless steel stencil from them, but it definitely didn't match my solder paste gerbers, wtf? They must have derived solder paste. Qualtity of stencil was fine, frame was clumsy to handle though.
• Extended voids between copper pads for the LEDs. Apparently the clearance was insufficient.
• tl;dr never again.

Second supplier:

• No problems!
• Silkscreen was much sharper
• Drill hits slightly better
• Soldermask was sharper
• No copper drama
• Edge routing quality wasn't quite as good
• One board has a short between the LC filter rail and ground. None of the others boards had this problem and I'll be on the lookout in the future before assembly. The short was "resolved" by blowing it away by hooking up the battery directly and converting copper to magic smoke. Boom baby.
• Ordered 10 boards, got 11.
• Board cost is cheaper (What the hell? HOW!? China, sometimes I love you.)

I've ordered a USB microscope and will do post on my blog at some point I think with high rest pictures.