I have some pictures for everybody to see:
https://picasaweb.google.com/1036324...nRevoltFailure
I'm waiting for new power PCB from Paul which should be better than etched version. Mine likely had insulation failure (heatshrink wear problem). I had two-piece heatsink as you can see from the pictures and holes had some burr and sharp edges when I opened the assembly. Those might have caused excessive wear too.