This is an update to my previous spin. I've fixed all of the issues! Version two has:

• PIC12F615 - 8 pin SOIC - or any other PIC with the same pinout
• Two 1k resistors - 1206
• Two LEDs - 1206
• Pushbutton, two pin - through hole
• Debounce capacitor - 0805
• Two 4-pin headers, one on each side, for the PIC breakout
• One 6-pin ICSP (in-circuit serial programmer) header for PIC programming

Here're the improvements I made, and some I'd like to make. In order of importance, improvements:

• Fixed headers to use 1mm drills. Otherwise, manufacturing variance may prevent proper header use!
• Fixed the ground plane issue.
• Tented vias with 12mil drills instead of 25mil drills.
• Fixed silkscreens for headers to be symmetrical.
• Fixed LED silkscreen to show polarity.
• Components no longer too close for inexperienced solderers.
• PIC moved to the bottom of the board, along with debounce capacitor.
• Kept 1206. Size is I/O bound, so no need to reduce size.
• Reduced board size to minimal rectangle as defined by the headers (so size is I/O bound).

So I fixed just about everything wrong with the first design. Some future changes are:

• Add signal names to top silkscreen (they are currently only on the bottom.)
• Change to a surface mount pushbutton.
• Validate other 8-pin PICs that have the same VSS/VDD/MCLR/PGD/PGC positions.
• Following that, use a PIC with UART and put LEDs on rx/tx.

However, it appears that I am pretty much done for now with the design. I'll probably make a third spin but it's not critical since things work perfectly as-is. The biggest weakness today is that the pinout has been flipped vertically from the datasheet; this can easily be remedied with proper documentation (which means people aren't referring to the datasheet pinout.)

Some relevant past work:
Pre-programming the PIC
Gerber renders (I'll post the real gerbers soon)
OSH Park renders
New board exuberance