martin, the way I would proceed is to replace the caps with 1000uF 25V radial caps rated at at least 105deg. C. Something [http://www.digikey.com/product-detail/en/ECA-1EHG102/P5544-ND/245143|like this] should work. The diameter on those is only 10mm, so it will give you back some real estate :-) Since you seem to have space issues on the board with the bigger caps, it is okay to bend them somewhat. Just make sure that they are soldered properly so as to not create fractured solder joints when bending. Place some thin heat shrink insulators on the legs of the caps so that they do not touch each other. Right now it is possible that you either have a cold/fractured solder joint,a cap that fails due to poor temp control since there is no heatsink. Hope this helps, good luck.
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martin, the way I would proceed is to replace the caps with 1000uF 25V radial caps rated at at least 105deg. C. Something [http://www.digikey.com/product-detail/en/ECA-1EHG102/P5544-ND/245143|like this] should work. The diameter on those is only 10mm, so it will give you back some real estate :-) There are also 1000uF 35V caps that have the same diameter, but they are a bit harder to come by. A search on mouser.com or digikey.com should help you find those, even so the 35V is a bit unnecessary. Since you seem to have space issues on the board with the bigger caps, it is okay to bend them somewhat. Just make sure that they are soldered properly so as to not create fractured solder joints when bending. Place some thin heat shrink insulators on the legs of the caps so that they do not touch each other. Right now it is possible that you either have a cold/fractured solder joint,a cap that fails due to poor temp control since there is no heatsink. Hope this helps, good luck.
martin, the way I would proceed is to replace the caps with 1000uF 25V radial caps rated at at least 105deg. C. Something [http://www.digikey.com/product-detail/en/ECA-1EHG102/P5544-ND/245143|like this] should work. The diameter on those is only 10mm, so it will give you back some real estate :-) Since you seem to have space issues on the board with the bigger caps, it is okay to bend them somewhat. Just make sure that they are soldered properly so as to not create fractured solder joints when bending. Place some thin heat shrink insulators on the legs of the caps so that they do not touch each other. Right now it is possible that you either have a cold/fractured solder joint,a cap that fails due to poor temp control since there is no heatsink. Hope this helps, good luck.