Hi David,
Great to hear you got the current down - too bad I couldn't be there to share a round!

Was thinking about the 30 uA... Even that seems a bit high for sleep (if I remeber, with all the extra stuff off, a '628 should idle around 5uA or so).

Unless you're using them - you might check to see if all the analog stuff is OFF, brown-out detect is OFF, and there are no 'floating' input pins.

To eliminate pullup current in software, you could just make the pin a LOW output when you're done checking its state - pullups are disabled when pin is an output.
If you do this, use a resistor of about 330 ohms in series with your pull-down switch, in case the pin ever goes output HIGH for any reason (don't want a short!).

Arch