Hi Art,
Nice project!
I know you're pretty far along in the design so please forgive me for jumping in with suggestions at such a late date.
Have you considered using some of the bargain "surplus" or "new old stock" 8x8 matrix displays out there? You could probably replace $30 worth of discrete LEDs with three 8x8 modules (8x24 = 192 LEDs) for less then $5. Use SIL (single in-line) machined pin headers for module sockets and you can utilize the space under the matrix modules for other circuitry (notice how much room I have under those large 2.2-inch modules in the pictures below).
Have you considered scanning rows instead of columns? This would increase the duty cycle from 1/18th to 1/8th which should improve brightness by increasing "average" LED current. Using "direct" I/O drive on the rows is limiting you to about 1.3-ma "average" current with your 1/18th duty cycle. That would go up to about 3-ma "average" current with a 1/8th duty cycle.
Kind regards, Mike
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