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Wherewolf is looking into all that stuff with the pcb and vias. I know the mosfets failed shorted when the controller was turned off, and the legs blew off because of excessive current once it was turned on again. I've taken care of the mosfets not sitting flat against the heat spreader and the pcb. I think it will be OK until vias become available. We are probably going to go with 6 ounce copper, so it wouldn't be bad to cut little isolated islands on the capacitor side for the mosfet/diode legs to poke through, and still allow the capacitor current not to be too high for the copper paths.
I talked to a couple experts, and I'm getting closer to the control section being done really well.
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