Oh yeah, the fabrication plant I used was able to create proper boards.
I haven't had any problems with reliability. I've built 8 complete sets of 128MB now, and all have worked fine in my two IIfx testbeds. It's conceivable that I could have received some on the very low end of the scale at 1.17mm, which would be below threshold. So far, out of the ones I have built, they are all .050" exactly on the micrometer across the fingers. I did use 2oz copper, I wonder if that makes the surface copper layers thicker?
About Rominator, I have 3 of them, and have never had to use tricks to get good contact. SIMMs should have a tolerance from 1.19 to 1.37. Standard fabrication tolerance is ±10%, so if BMoW used 1.2mm substrate, he must have received some batches on the bottom of that tolerance scale. I should measure mine.
Great! I'm pretty sure the port was originally designed for the 2/5 (hence the "25" in "LISA25.SYS").
This is one of the reasons I get a strong feeling that this wasn't ever really finished; it was a demo platform, rather than a serious port. Error handling is nonexistent (if you get an abort/retry/ignore prompt and press 'r' for retry, it actually restarts the machine, at least here). I have found so many ways to crash this so far
So it boots off an X/Profile on a 2/5. HELLO.APP works, but 1ST_WORD.APP causes a complete system hang when trying to create a new document. Make sure to have a floppy disk inserted if you try to access the drive, otherwise it will crash the system with Lisa Error 47.
Also: don't forget to copy ASSIGN.SYS and LISA25.SYS to the hard drive when doing your file copies.