You are a genius, dude. That was it! After stripping the stupid header, I was able to play Liquid Kids!!!
Ok, I have a little more testing to do with my PC-Engine, and then I am going to ship the proto-card to 'thesteve', where he can test it on multiple systems. After that, I am going to have production pcbs made, and order all the components.
I have come up with a final price of $45 for the flash HuCard. I know that's a little higher than my original estimations, but there were a couple factors that raised the price: 1) the pcb needs to be a custom thickness (not the standard .062") and 2) the added cost of gold flash on the edge connectors. At that price, I will still be able to make a little money for my time (both development and assembly), and reinburse some of the development costs. Also, any money I make will go towards future pcb and component purchases if there seems to be demand for it.
We can keep this on the "down-low" until everyone here that wants a card has gotten one. After that, feel free to post about it wherever you like.
I have already started a website for the flash HuCard. It is just a first draft, but there is software and documents available if anyone wants to take an early look:
http://www.gamingenterprisesinc.com/Flash_HuCard/Thanks to everyone on this board for their help, and enthusiasm which helped keep me motivated.