Hi, folks. New Tricks, if you haven't found a solution to your problem, I might venture a couple suggestions. You can use the pedal inputs in a couple different ways, and I think they can probably get you where you need to be. You can use fairly inexpensive pedals, all they need to be is a momentary switch. It sounds like I do a lot of what you're doing (calling up sequenced/sampled horns, keys, latin percussion, etc, to fill in blanks) and I use Boss FS-5Us. If simply using the pedals to trigger more sounds isn't enough, you can also program them (or pads, for that matter) to scroll up or down thru your various kits. If you really have that many unique sounds you need to call up during one song, spread it out over two kits, and use the pedal(s) and/or pad(s) to switch kits during the performance. I've also found that some passages, say a horn lick, will be shorter for the first time around, and longer later in the song. Sample the whole "long" passage, and set the pad or pedal you're using to trigger it to "ALT." When you need the "short" passage, trigger it, then hit that pad or pedal again to stop the playback at the appropriate time. When you need the longer passage, just go ahead and let it play out. The horn lines in Santana's "Smooth" would be one good example of how I use this method. Doing this, and/or switching kits mid-song should allow you to accomplish your goals, or at least get closer. Anyway, I'd think two external pads on each side of your drum kit, and two pedals in addition to the SPD-SX's pads should be plenty once you work out the logistics.
As for opening up the SPD-SX to attempt repairs, I recommend strongly against it. My headphone jack was starting to go a little wonky, so I thought I'd open 'er up and check it out since it was so relatively easy to replace the capacitors in the old SPD-S as explained in this thread. Wrong. The SPD-SX is much more difficult to get apart, and once I finally HAD to do it, I was in constant fear that I was going to damage the thing irreversibly. I had to do it because when I'd removed all the screws, the two pieces of the housing still didn't want to come apart. I shook and jiggled and peered and pried, and still no joy. I figured there must be another screw or something under the rubber pad piece, so I took that off to have a look. It's pretty easy to peel off, BUT DO NOT DO IT. There are no screws or latches under there, and once it's off, you HAVE to get the case apart to get it back on properly. It's held down by little rubber nibs that fit into holes in the casing. Pulling them out is no problem, but you cannot push them back thru the holes. You have to get the case apart and PULL them thru from the back side. I honestly don't know what was holding the case together, but I did manage to get it apart without breaking anything. The gain knob on the back is one impediment, but I still think there's more to it than that. Maybe it was just mine being a little extra sticky. Anyway, once you get the two pieces free from each other, you'll find that the PCB where the USB jacks reside is held on to the bottom casing with four screws, and ribbon cabled to the rest of the PCBs. I didn't want to risk damaging the ribbon cables, so I took out the screws, which was no mean feat with no more room than you have. And while I was in there, I saw that there are really no "old-school" thru-hole capacitors or other components. It's all surface-mount stuff which would be quite a challenge to replace or repair (at least for a novice to intermediate de-soldering guy, such as myself). I didn't see any obvious cold solder joints or anything amiss with the headphone jack, so I left it be, and put the SPD-SX back together carefully, after pulling the rubber niblets back into their holes to replace the rubber pad. I'd say it was a nightmare, and I will not undertake it again lightly. I apologize that I didn't take pictures, but I was getting down to the wire on having a show to play, and I'm currently using the SPD-SX as my whole kit, minus a couple cymbals. So while I was able to get an extra 6-8 months out of the trusty old SPD-S, I don't think the SPD-SX is going to be the same kind of story. And that's my story.
Special thanks to Fuzrock for getting me the aforementioned 6-8 months, and thanks to you all for reading my novella here. Hopefully it will save someone the headache and nerve-wracking ordeal I put myself through. And at least for the past couple shows, I haven't had any problems with the headphone jack. Knock on wood. lol
-Russ