Hi bart, thanks for the link.
I'm not opposed to using a different chip I just need to keep it as simple as possible both in terms of components and programming it. The 4000 doesn't list either pushbutton or MCU as it's control option so that does scare me a bit.
you can do with the 2500 serie too, you'll need more i/o for sure (for adress management and push button) It can be a bit more easy to program but don't be so afraid with the 4002 serie. Let's work together on that with all the PBC statement.

Now, about the PIC itself. With your suggestion of the 16 I/O ports that leaves just 3 for the sound chip control. Whatever happens it would have to remain in that limit for the 5 different sounds or I need a different PIC.
10 leds+5 pushbuttons+4 chipcorder = 19 i/o
O.k. now have a 28 pins PIC wich will give you about 20-25 i/o. PIC16F870 PIC16F872,PIC18F2220 could be great choices.

I'll stick to the surface mount stuff. Too much overhead to invest in the X-ray machine and probably a computer to do it the other way! :-)
I heard about a million $ about the X-Ray machine... a bit expensive for experiment purpose :0)

P.S. edit to say you probably figured this out, but I will want to make a recording circuit which can have as many parts as it needs to have a line in from the computer to record then the playback circuit which has the bare minimum for parts.
smart move or something like testpoint/edge connector jig to access to it in-circuit. BTW for the recording stuff you just need 2 capacitor and a maximum of 4 resistors. Edge connector with ICSP capability and Line in will be sufficient IMO.