Did the geometry changes help?
I am busy making my own PCB... I don't normally do this >_< I amusingly haven't needed to yet!
One disadvantage to rolling your own design for the mounts - can't just use your PCB! BUT lots of fun anyway
Could I perhaps get the CAD files for your PCB? I need to have specific mounting holes and such so it would be a great help if possible. If not I just have to figure out how to do this!
What was the advantage with the aligned sensors? i.e. can't you just have no deadzone and the initialisation code deal with it?