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You guys are right on track. I'll throw in some stuff that might help.
1. Remember that each relay output has 2 bits - so to transfer an 8 bit value from one processor to the other you only need 4 relay outputs.
2. If you read the digital inputs while the other processor is changing them, you can read a corrupted byte. You'll need to figure out some way to ensure that the data that came across the digital ins is valid.
3. I think that the PWM outs from the RC never go full DC. Even at 0 or 255 they're still pulsing, I believe. I'll try to remember to check this tomorrow on the scope, unless someone else can confirm this.
4. Finally, if you have any engineers on your team who have some experience with it, I'd highly recommend trying to use some other processor than the stamp. If you get a HC08 or a PIC you'll get a processor that is orders of magnitude faster, cheaper, and not that much more difficult to program.
Doing a microcontroller based custom circuit is a lot of work but it's fun and it's a great learning experience. We had a good time building ours last year and we're well on our way to having a plan for this year's.
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