Morgan,

I think you have done a good job in understanding the problem.
It shows you are actually thinking about having the thing work.

I have done lots of control stuff like this and never have had a problem 
because I used the Opto Isolated Hockey Block looking things.
You are working off the mains at 220V,  watch out!  Your mods would not pass 
safely many places I worked.

The problem is your CHEAP customer, you need to get them to fess up for 
another dollar and some board space!  A bigger relay would probably be the 
cheapest?  Look at all the labor in adding stuff external in heat shrink. 
Where is the heat going to go?  Mechanically, will it stay together?
Where are the fuses on the 220V that will blow if the part gets hot and the 
shrink sleeve splits!

I don't think (as an engineer) you should be a part of a Mickey Mouse fix!

I would not like to buy their product based on what you say about them.
They need to listen to their engineer (YOU), before all the failures and 
loss of business starts.

They have put you in a bad spot, which typically happens when you have to go 
back and fix a bad design.  They want it fixed, but box you in with 
constraints that can't be met.  They need to think of their customer and 
competition before you all are out of work.  They can't let their "Bean 
Counters" decide the engineering.

It sounds like you have been patient and are trying to really help them.
Is there any way you could smooth talk them into doing the right thing?

Yes, it is "Politics" again.

I hope you can come out the Hero!


Mike
Who always designed things that "THEY" said were too expensieve, but worked 
Forever!  Now put out to pasture at 60 years young because of some of the 
same situations!
Crestline, Ca. USA

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