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I had one on breadboard (it's now half-finished on a circuit board) and I rolled my own vactrol out of a photoresistor and an LED, but I did find that the sensitivity was heavily dependent on the LDR I used.  The first one I used was very subtle but the second one immediately put the clamps right down on my signal (that's the one I went with).  Best I can tell, the relevant quantity for sensitivity is bright resistance of the LDR.  Are you using a vactrol VTL5C3?

Yes, I'm using the vactrol VTL5C3. I already boxed it up and everything, so there's not much room for tinkering. I'd like to set it once and forget it. I'm thinking of making R7 either 56K or 68K.

Do you all find the stock value for sensitivity to be suitable for your instruments? I use it at the front of my chain, and find that I'm having the sustain set almost at max. If I use a low output guitar, the effect seems too subtle. Perhaps I got a higher resistance vactrol than average.

The transformer should be fine, should clear in a few days. Think of it from their perspective... "this thing is heavy, has a bunch of wires coming off of it, and I don't know what it is...better check into it"

+1 to pickguardian. I ordered a rickenbacker pickguard and it was perfect.

A few manufacturers use long pin pots to accommodate the stomp switch and 1/4" jacks to all be pcb mounted. I'm wondering if a pcb mount toggle or slide switch exists that can also be used on such a board. The switch would need to be panel accessible like the pots/stomp switch. The long pin pots have a clearance of 20.7mm from top of board to the enclosure. I've found a new series by e-switch that accommodates this height, but nobody seems to have them in stock.

The tech 21 pedals have a slide switch like this, but I can't find the part number:
http://www.talkbass.com/threads/show-your-pedal-guts.653387/page-6

I was wondering if anyone has had any recent experiences with Pedal Parts Plus UV Printing.

Some people were experiencing problems in the beginning:
http://www.madbeanpedals.com/forum/index.php?topic=9110.60

Have they sorted out the inconsistencies? Would you recommend the service, or is Mammoth screen printing preferred?