RJ,
i was looking over the express board and i came across something which i think could be improved on to help increase the safety of the design .
i was looking at the position of the current limiting resistors for the led indicators. I think it would be a safer design to move them from the high voltage side of the opto's to the low voltage side.
This would inprove the minimum seperation between the 2 sides from about 1mm to 6mm.
With the current design it wouldnt be hard to get a solder bridge between the top of the resistor and pin 6 of the MOC creating a short from the mains voltage to the logic side of the board.
being that you have another coop on the way now would probably be a good time to do the redesign.
regards
Peter