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The only rotary switch that is going to fit in that space is exactly the one listed in the BOM. Anything else will require wiring it off-board and a larger enclosure.

I'll be ordering 100 boards for the initial run. This should be enough to stay in stock for a couple of weeks, even if it does sell well.

Not only that, but a circuit as complicated as the Dirtbag requires more testing to make sure it's been vetted as much as possible.  If there turn out to be issues, it would result in a whole lot of help needed threads and frustrated builders.

Don't get me wrong, I COMPLETELY get this.  But if we're still in the prototyping and testing phase, maybe don't publish that's it's coming out this month.

In a perfect world I would not. But, there are also only so many emails I'm going to be able to tolerate with "when is xyz coming out?" So, either way someone is disappointed...but one way gets me off the hook for a while 

Time for the tough love: did you test it before putting it in the enclosure? If so, and it worked, then concentrate on the bypass switching first. If not, well then you need to take it apart and test just the effect by itself to eliminate the possibility of I/O problems.

It will definitely be out before Half-Life 3.

Your PT2399 voltages look good. The problem is in your VC and VB voltages (referring to the schematic). You should have closer to 8.5 on pin8 of both ICs, and you instead have just above 6v. This appears to impact your VB voltage, too.

Assuming you are using a steady 9v supply, I think you have installed the wrong value on R28. Can we see a pic of the top of your board? I want to see what resistors you have on R28, 29 and 30.

I spoke too soon. The FR-300 is being returned. Unfortunately, I got a defective unit and it appears that the temperature sensor is toast. The nozzle doesn't heat any longer. So, I will get a replacement and hopefully that one will be okay!

It's fine to use either version of that TL062 or even a TL072. That's not the issue.

For voltages attach the black lead from your DMM to the circuit ground and use the red lead to get the DC voltages from the IC pins.

Taking voltage measurements and audio probing the inputs and outputs of the IC's are what I would do.

It's "next batch" for sure. The release date is fluid but it will be in the next batch of releases, absolutely. I'm taking my time with this....frustrating, I know. But, necessary.

D8 is not part of the signal path, but is there to prevent the PT2399 from clipping too hard from the input gain stage.

I can't put my finger on it though....hmm.

So nice to find these things AFTER you build them.

Yup, that doggie can play!

So, they are both pretty awesome. I've put in a fair amount of time with the solder pen. It works so well, and the unit heats up in less than 10 seconds! The desolder gun is larger than I thought and sounds like a dying yak when you pull the trigger, but it really does miles better than my previous one. It actually pulls all the solder out of the pads in one go most of the time.

So, I guess I can say it was probably worth the money. 

Get well soon! I had an appendectomy when I was 21. The recovery is pretty quick...you should be up and about within a couple of days. Good news is that scar will heal up nicely...mine is barely noticeable 20 yrs on. I remember walking around campus from class to class hopped up on pain meds. Kind of a funny memory to take away.