I have one idea, I'd like opinions on it please. Lack of experience prevents me from knowing if I am just heading for another set of problems.
How about adding a PIC 16F628 to poll the MCP23016 and use hardware USART to send a word whenever data from the I/O Expander changes?
I checked the datasheet and the 16F628 can go up to 5000 KBAUD at 20MHz while in Synchronous mode. Is that fast enough without the USB service dropping?
Robert
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can you refresh my single workable brain cell on this friday before i left home to night club 

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