It's the cost of custom headers and larger dual PCB layout that makes me want to avoid that solution. Wish the part was available in PLCC form. The Schmartboard is looking better and better, also the kits is not for first timers so I would hope the more experienced PIC users / builders would be most interested.
Ok, can't beat a solid argument I'll keep the SD card (and space permitting a EEPROM socket option)
5V switch mode wall wart with a 3.3V linear regulator (5V is for relay power on the I/O connectors which will be pin compatible with the EasyPIC series devices)
Or
9 - 15VDC unregulated (also for relay power on optional octal relay board, and/or other future add ons such a octal opto input board)
PCB layout will be the following connectors along the same side
2.5mm PWR Jack, RS485 (3 screw terminals), RS232 DCE (DE9M), Ethernet RJ45, SD card
Internal connectors / misc will be
Two 8 bit I/O expansion connectors (10pin), XBee, ICD connector, Reset button
As of today the current I/O and pincount (we have 39 on the 18F67J60)
I/O required plus description
16 Two 8 bit I/O conectors (2x5 jack or 10 pin inline undecided)
2 ICD & SD RW & Insert (jumper selectable) PGC & PGD are 5V tolerent so will work with Junebug / Inchworm / PICkit2 / ICD2 etc...
2 Ethernet LEDs
4 SDCard (SPI)
4 RS232 EUSART with CTS / RTS
2 RS485 Software UART
4 XBee Software UART with CTS / RTS
4 25MHz & 32,768Hz crystals
Total = 38
One pin left... what to do? LED, iButton, analog input, interrupt input, CCPx I/O, 433MHz RF TX or RX?
A typical PCI18F67J60 design looks like this one from Olimex (pdf attachment)