I think you should use 220R. It makes your led brighter.
Yeah, I think 16F628 is the best choice between small chips. it replaces for 16F84, has more functions, but cheaper. However, it's more difficult to buy, and with ORCAD, you cannot get F628 component. However, I remember that I found somewhere an addin lib that provide 16F628 and 16F877 components for ORCAD. I used ORCAD 9.2 but it doesn't has these components.
I lost my data, I cannot send it to you. If you find it somewhere, pls email meeh.
The power supply, you do not need to use many cap like this, you can make it as simple as the datasheet of regulator. It makes your board smaller.
About pcb, I don't know why, but I think make your own pcb is very easy in vietnam. First of all, you need a little of FeCl3, drop it into water. You can print your board onto a the smooth and shiny of a decan paper. A decan paper (it's like paper hangings, I don't know how to explain it in Eng, I'm in vietnam). The back of the decan (the waste part, the back of a decan that you don't use) Oh oh.. stuff...
I really don't know how to explain
...
you print your board onto it than iron it onto a copper board. After that, you dip the copper board in liquid of FeCl3.
You can build a 10cm x 10 cm pcb in 15 minutes.
Goodluck