Quick update:
1) PS/2 issues resolved. Funny characters were eliminated by moving the samples into SPI Flash memory instead, and intermittent functionality was resolved by hardwiring the PS2 pins from the teensy straight into the USB wires of the minipac. Problem solved. Works great
2) samples are now loading in FLASH rom giving me 16Mb of low latency, low CPU load access to samples. Polyphony increased 2 fold, now looking at 8 to 9 44Khz mono samples running at the same time. C locked at 120Mhz for reference. Could be doubled if I go for 44khz 8bit u-law, i'll keep this option in the back pocket if i run out of CPU time.
3) Playing with a sequencer now, struggled at first but timing is now working better. Had to use multiple timer libraries to get a good balance of sequencer / lcd update / loop priority. Getting there with one bar at the moment. LCD now has button feedback and a sequencer position bar system in place.
4) Button upgrade. I stupidly economised when i bought the bits and used the cheapest microswitches they sold. This was DUMB. I am building a musical instrument, and the buttons are the keys to my piano.
The buttons were far too heavy to press, it was quite tiring. So i removed the springs so only the microswitch resistance is applied to the button press. This was much improved but I still felt it was too heavy (and loud!), we want a very light press to work just fine.
So I have bought 16 x Rolls Royce microswitches Cherry D44X, which are AWESOME. quieter click, much lighter touch to trigger. I also bought one of the Sanwa buttons used on the MidiFighter which DJTechtools did loads of research on to design. They chose Sanwa as the best switch for the job, and once I've got the Cherry microswitches in the feel is very very similiar, in fact I prefer the feel of mine over the Sanwa switch - there is not much in it. Happy Bunny indeed.
Next up: Pad LED output, rotary encoder, pots, panel LEDs, and finish all the wiring up for stage 1, so i can tidy up and get on with the code. Still need to put a backplate in with sockets/buttons for reset, line outs, usb, headphones, microphone etc. One step at a time.