@Mr.Blinky may beat me to this but I think I may have found the issue. Just getting some pics to explain, so have a quick sweepstake to see who’s right. I believe you have all had enough info to spot the error that I think it might be.
Now to figure out if I can greenwire it to confirm, before a board rev.
Actually I didn’t until you pointed it out.
I’m so gratified.
So board respin it is then. Thanks for playing along at home with me - it really kept me going. I can at least get on with testing a few more things before I send the board off, just in case we find any more hilarious errors!
And now, back to our scheduled programme
Absolutely! Couldn’t have done it without everyone helping.
I’m wondering if it’s still comfortable in your hands with some headphones plugged in. It looks like the plug will be sticking out into the palm of your hand a bit. Might be something to test before doing a respin.
Wow, I’m so glad you mentioned this. From an ergonomic perspective, I think you’re probably right - the jack needs to be more aligned with the sides/battery axis.
However, the real save you have just provided is when I look at the PCB, none of the jack pads are connected to nets. I have checked why and it’s because the schematic part uses letters for its pin numbers and the footprint uses numbers, like every other part does. I will do some proper revision in that area!