Clean connectors are just as important as new caps! Does BLACKOUT use Molex/Trifurcon connectors for the boards? I know they have a limited lifespan in terms of the number of times they can be disconnected and reconnected, but getting the header pins nice and clean usually does the trick. Point in case was when I cleaned the EOS switches in my VECTOR flippers. Nearly doubled the power because once cleaned they were conducting the current so much better!
BTW, just wondering on those large green bonus inserts above the flippers: are they really badly cupped or is it just the photograph playing tricks? Did you fill them with clear? Are the so bad as to affect play? Just curious...