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> The biggest hurdle here is probably getting your boards made--it'll be expensive and slow compared to everything else you're doing.

I guess it's a relative thing but compared to what it used to be I don't think getting PCBs made these days is expensive or particularly slow. (Well, slow is a couple of weeks compared to seconds for a compile cycle I guess...)

A few months ago I got two simple board designs fabricated at a couple of online PCB manufacturers and it cost under $20 per order with around two weeks for delivery from each vendor--for between three and ten copies of each design.

These are my notes on the experience:

http://www.labradoc.com/i/follower/p/notes-seeedstudio-fusio...

http://www.labradoc.com/i/follower/p/notes-osh-park-pcb-kica...




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