Don, here I thought I was the only one. I had the same issue on my first board of five. 6 pin sockets were all to big, got them in but it was a fight. Triacs, 5V and 3V all had to be filed down.Aand as you said the LED's would not sit flush. I was expecting the green power connectors to act up so i had pre-emptively taken the dremel to those.
Now this was the first board I had ever done so I thought it was just me. Kinda glad to see others had the same problems.
I don't mind shaving the triacs and 3/5 volt pins or having the led sit a little high, but the 6 pin sockets were the biggest pain.
Anyone have any hints on those?
Thanks,
Richard