I just received my Tsunami and went to fit it into the aluminum case. Unfortunately, the board will not slide into the case — this is due to excess solder on one of the mounting pins on the OUT BNC connector creating a conical bump.
Additionally, many other of the through-hole pins (BNC center pins, blue button) look like they're touching or almost touching the case (with the board inserted as far as it will go) and could short out.
It looks like these two problems can be fixed straightforwardly with a soldering iron to remove the extra solder and cutters to remove the extra (past the soldered region) wire, but I just wanted to provide the report and warning.
I don't have time right now to experiment with programming the board, but it does produce a blinking green light and a tone on the output port. (I suggest not testing it by attaching headphones, or at least not wearing the headphones when you do. Ow.) Speaking of which, it'd also be nice if there was hardware documentation (I didn't find anything on the wiki other than programming instructions), for such things as "what does the program it's shipped with do", "what does the blue button do", and "what is safe to connect to the ports".
My board was the same way. I used a pair of flush cutters to remove some of the extra length on slender pins extending too far below the bottom. I used a file to knock down the conical bumps you described, and then just carefully inspected with a back light to make sure there was adequate clearance when the board was inserted in the enclosure.
All good points, thanks. The longer pins on the BNCs do need clipping short, but none of the others are long enough to make contact with the case. The manufacturing samples I received did not have bumps on the alignment posts, probably because they were hand-soldered but the production units were selective soldered. Sorry about that.
I'll put together a datasheet and stick it on the Wiki as soon as I have a chance - it may be a couple of weeks, as I'm out of the country, unfortunately.
Thanks for the suggestion of a file; I actually had one ready to hand. I just filed down all the protrusions in a row at once until it fit with a comfortable clearance (and of course cleaned off the metal dust afterward) — not as clean or fast as cutting but it's done now.