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Conformal coat with nail polish or polyerethane ;)
Math is wrong12vdc at 8 ohms would only pull approx 1.5A at around 18watts...and only drop as he says when the heat of the board increases
Electroplating would add metal to the traces, which would lower resistance and increase current flow, you want a smooth dielectric, like clear coat high temp paint or something, nail polish, polyerethane
I use clear nail polish, or the fast dry minwax polyurethane in the spray paint can (stuff they use to protect hardwood floors)Apply a coat, let it dry, then maybe 2-3 more coats and voila...instant conformal coating and no need to heatshrink or use hot glue
I use clear 2 part epoxy on my pen drives, coat them then stick the case back on..man are they protected after that
Can you put your .brd on OSHPark?
Believe it or not, a simple tiny drop of clear silicon (GE silicon II or whatever) or even 2 part epoxy (like JB Quickweld works great...just make sure you use a VERY thin layer, once bonded, they ain't coming off and thermal resistance is minimal (heat has to go thru the plastic case anyway) if you use a thin layer.
Ever thought of taking SPI out of the Atmega 168 directly to a MAC enabled ethernet chip?http://www.microchip.com/wwwproducts/en/en022889
Correction the Wiznet W5100 ethernet http://www.wiznet.co.kr/product-item/w5100/
Conformal coat the boards with clear nail polish on initial purchase and on repair...the electronics and connections will last MUCH MUCH longer
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