Finally took some time to get out the tools and work on this b!itch -
#1 trough not detecting balls correctly - removed and reseated connectors - fixed for now
#2 mode start trough not detecting balls correctly - had to custom bend the switch wireform to allow switch to open when trough is empty - seems to work now
#3 Xenomorph targets - after removing some of the material on the left brace that was good - right target had to move forward and then bend the brace back to allow enough clearance to allow the switch to work and the mouth to open. Tight tolerance there, but working now.
#4 Ball launch still having issues - planning on making a custom wedge to align the shooter - still open.
New issue - mode kickout seems not very smooth - looks like it hits the lip of the wood hole in the front. Will have to figure out how to tweak the unit.
At least I can play a friggin game at this point. And to be clear - I love the game, but it was f'd up big time when I got it.