That sounds like a good idea. I'll take apart the jumper pak and see how much shorter I can get it. I've got no problem tweaking the insides to make it fit better, but I'd like to keep the expansion port there for aesthetic reasons if nothing else.
Having said that, the top side of the motherboard is facing the back. RCP wiring would be extremely difficult given it's got to then go over the top or around the side of the board. Given the damage to this chip though (not the RCP, the other big one) I'm curious as to whether it works now, but if it doesn't I still have another 2 boards here that I can put in place. I accidentally cut through the leg too far when fixing it. I assumed it worked but unless this is just a redundant leg, I won't know. Just got to resize and upload a picture, you guys will be able to tell me if I need to fix it to get it working (highly likely)
I'm still toying with the idea of building my own board, although this still wouldn't solve the jumper pak problem as I would have to remove and replace the actual port. I've PM'd Kibble and asked if he can give me a boost start by sending his eagle files, but I haven't had a response just yet. I'm still not convinced it would work, but hopefully any modifications I make would give me a starting point for PAL boards, whether its for this project or for another.
I think if I went down the route of hard-wiring in the jumper pak I may as well splash out for the expansion. Who knows, if I sell this in the future the new owner might want that capability but not have the skill of putting it in themselves. I could just glue the port shut and it would just be for aesthetics.
How much do the expansion cards cost these days?
UPDATE:
Photo
After I filed down the rust and broke the 2 pins, I shaved down the board to repair. In the process I severed 2 more pins (doh) and fingers crossed that the original 2 I broke were used for something important, and the 2 I severed were worthless. Looking at it, I doubt it. Still, they're easy to fix, I just need my laser vision and thin copper (I just have to clean the crap out of the wound, so to speak, you can see how much crap is there)