[Cuog]

Im not sure if you mentioned this already but it deserves repeating(I only scimmed after reading half). MODULAR. Use alot of small Functions written by members that do very specific tasks. Don't be affraid to have call trees that are very long. It will save time and recoding later.

Heres an example:

User Routines();
>void Map_Joystick_to_PEM();
>>unsigned char Lookup_Map_Curve(unsigned char Joystick_Value);

And all that stuff because if anyone needs that calculation one call
can save each person the time to write the code that does that same thing three different ways. This again saves on debug time, since we all don't have enough time anyway.