here is a quote from the same thread on URC

"I have heard of this being done, but I think that was on earlier model revisions. Later revisions had "improved" firmware which prohibited the extra channel features, even if the hardware were fitted. But if you do have an earlier model, then yes you can fit the extra switch hardware and have up to 5 channels."

That could explain the firmware hiccup in the first couple.

Rusty, wanna try it out tomorrow? I have a couple toggles lying around.