WOW this is so awesome. I hadn't checked back at this thread for a while and am amazed at all the great work. I had thought to make a PCB but my Eagle skills are non-existent so I'm very grateful that folks have taken the time to do this. Looks excellent.
I had a small update on my end; I completed an enclosure for the device. I've uploaded some pics here:
The enclosure is cherry, lexan and 4 flat head stainless steel bolts to dress it up.
Again, for whatever reason I can't figure out how to get some decent pics of it.
Some Video: http://www.youtube.com/watch?v=j6nK33QI-So
Also had a video up on YouTube of my daughter playing with it. http://www.youtube.com/watch?v=QMKiN_5nrUI
What's great about this is the kids. They love it and it's a great learning tool. My youngest uses it to learn colors (red + blue = purple) and my daughter uses it to learn letters.
Overall this is was a great little project. Again, really excited to see where you guys take it.
Keep us posted.