Clearer markings for connectors/locations/"top". Definitely can do those, good reminder.
Power LED, trying to find an easy way to do that actually. But may not be feasible without a steady ground path, which would involve more wiring. Theoretically wouldn't be too hard on the AUX adapters, but will be a while until I need more of them. If I did a single LED tied to a specific output it would work, though would be a 'blinker'. If I can find a way to make it steady, I do like the idea, just not sure how yet.
An SMT LED on each output is a really cool idea. From a design standpoint not too hard either. But best pricing for LED's would be about 4 cents each, maybe a bit less in bulk. Would also double the machine time on my pick and place. Would increase the cost to customers by $10-$15 per set. Maybe as a future 'deluxe' version, but I don't think it would be as successful for a regular version.
The 90 connectors are long gone, that was a bad decision on my part, and I learned my lesson quite quickly with them. The current generation of boards is designed to get all the clearance problems worked out, while using a vertical connector of sufficient height, and I don't believe I've had any customers with issues using the current style connectors.
The connectors for the AUX boards, I totally feel your pain. I regularly look for different connector options, but the .156 style headers are less and less common all the time. I haven't found any other style of connectors. Even the Molex ones I have been using are sometimes tricky to get.
With the cable routing, are you saying the wiring needs to be longer? Which section? Getting the right AUX board wiring lengths has been difficult, very little feedback, and there's a LOT of variation.
And, yes, an instruction re-write is due.