I've never used ExpressPCB but have heard good things from some who have. But using their standard service, you're paying quite a bit per board... assuming an 8 square inch board it'd be $67+$7.25 per board+shipping. Production service would be $233+$4.28 per board+shipping. You'd need over 56 boards to justify moving up (and that'd be nearly 500 bucks worth of boards). Depends on how many you're interested in, I suppose. Still, I guess if enough people want a Ben board for less than $10, it could be worth it
I don't mean to sound as if I'm insulting your intelligence or doubt your abilities, since you've obviously fiddled with the Atari quite a lot over the years, but have you looked at the 2600CE page for possible answers to those questions? He's got a somewhat nice looking design up and running, it seems (wonder why it's never updated...)
Gannon: Nice design! I like it. How much stuff is involved on the internal controls side of things?