Steve,
You mentioned that you want to build a number of units for field beta testing. Could I volunteer to help you with that task. I'm down in San Diego. But if you plan to do this one weekend soon, I'll be glad to come up and give you hand. Hell, I'll even order pizza for the project. I think it would be a valuable experience for me getting practice on assembly and testing of components.
I work as a senior level software engineer (mostly assembler!). But it would be fun to put together a hardware project like this. I wish I could tell you that I am an experienced electrical assembler, but I not. What I lack in experience is made up for in enthusiasm and a willingness to learn.
Let me know what you need.
Ron