Hi, I was that customer and Rich proposed I should post some photos here.

Maybe someone has a good idea what else I could try before I give up the idea using my wonderful ZXpand also on my ZX80 machine?
This is my ZX80 "ISSUE 2A" PCB and I did the following modifications, before I wanted to try the ZXpand conversion kit:
I replaced the 2 electrolytic capacitors with new ones, I built in a "ZX8-CCB" video out mod and I replaced the old 7805 voltage regulator with a modern 5V Tracopower TSR 1-2450 DC-DC converter. The heatsink is not really needed anymore, but I kept it in. I use a modern strong voltage regulated power supply set to 9 Volts for DC input.
The machine runs fine with the old original Sinclair 4k ROM, I get a nice looking video signal, I can run, load and save Basic programs. I neither connected the ZXpand nor any other memory expansion so far. I can measure 4,98V on the power pins on my ROM socket.
Next I take out the original ROM and put in the replacement ROM, it sits in the socket perfectly no bent legs (see photos), I can see using my multimeter that I have contact for each pin of the replacement ROM down to the soler pads of the PCB, so the ROM socket is also fine.
When I switch on my machine (again neither the ZXpand nor a memory expansion is connected), the screen stays black and the machine is not booting up. I changed the relacement ROM with another one Rich sent me and I also replaced the Z80 CPU with another working one, no change in behaviour.
Rich had the idea now, that I put the replacement ROM in the wrong way, so I just tested that with 1 of the 2 replacement ROMs I got and I put it in the other way round (which would be the wrong way in my opinion) and as expected it got very hot after 2 seconds, so I switched it off immediately and this makes me pretty confident the first way was the correct one.
Anyway you can see all of that on the attached photos, both Z80 CPUs I tried, the working screen and both ROM types. If someone has any further good idea, it would be highly appreciated. Thanks, roli.