Built a new one with SD card and it works!
ESP is reading the SD card nicely.
New board seems to be bug free. Party time.
Now the question is, should I attach the Teensy Side to the SD card and thus the ESP8266 via SPI as well. This may mean I will have to change to a 6 layer board.
Next task. Indigogo project, lets see what the maker community make of this, see If I can sell 1000 units. Current price looks around $39 (NZD) so $26USD at current exchange rate.