OK, so I have a couple questions about assembly. First of all, the old chip has 16 pins, and the headers have 16 pins total, but the socket is only 14 pin. Are you just not using two of them?
Second, I had some difficulty with the 14 pin socket. I tried to push the header into it, but was unable to. Do you really just have to jam it in there? Are there headers with thinner pins available?
On a related note, I had some difficulty pushing the header directly into the circuit board, though I was able to eventually. Again, are there headers with thinner pins, or do you just have to put some effort into it?
Finally, do we know what’s causing these chips to die? I am guessing it is bad tantalum or other electrolytic caps on the board. One of the caps right next to the chip was testing about three times higher than it was supposed to.