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They wouldn't be dirt cheap either, but that mainly depends on how many people were interested. Having a just 1 of these made up costs around $50 as it is there, and that's done at a place that doesn't do any internal routing, which are cutouts done inside the board, like the square holes for the Trigger assemblies, so that has to be done afterwards with a Dremel, or the whole deal done at another PCB fabrication house that would charge more per board to do it on a machine.
Sorry, but I've no plans to release the Gerber files at this time, as that's on par with releasing source code for us hardware guys, since all the work went into making them. If you'd like to make your own homemade dual sided boards, drill all of the holes in the correct spots, then hand plate all of the Vias or put wires in them and then cut the thing out so it fits right, well, I'm not going to stop you, but I'm not jumping on that band wagon either. It's not any kind of money saver at all when the time to do all of that is factored in, and you still end up with a board that's nowhere near as nice as one made at a fab house. You also wouldn't need the Gerber files to do it that way either, just a couple of .jpg or .pdf files of the board traces/outline.
Making an LED board wouldn't be very hard, but the thickness of it's going to cause issues there and then you'd still have a mess of wires to deal with. The best way to go about that would be to make it with a Flex board, like the Intensafire or Viking one, but that entire thing (components installed) would have to be made up by some company since soldering on those things after the fact ends up in them melting 99% of the time. Making it so it has to be connected to the original LED lines is needed so the player indication will work, but it also limits it to one version controller or the other, Matrix or CG, as they each drive their LEDs in a different way, unless that's been taken care of in your code. The Matrix LEDs are in a Common Anode layout and so are driven with negative pulses, while the CG controllers are in a Common Cathode layout and driven with a positive voltage. That will also influence the Flex board design as well, since they each have components in different locations.
A hole has to be, well, a hole, round. Anything else is a route or slot. Making it a hole would make it too large for the part that has to fit in there. I could have the thing just drilled 6 or so times, the 4 corners and along the edges, making it less material to remove. That's the 'typical' way of getting around internal cutouts, but the 2 spots that need it are pretty small and wouldn't be a big deal to have to do by hand after the boards are made up.
ill take one. pm sent