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Thanks for the input Rob, some great suggestions which I'm going to use so standby for a redesigned version using transistors. Although won't there be the risk of a massive transient going through the transistor which will be activating the laptop PSU relay?
The Mega16 is WAY overspecced for this I agree, there are 2 main reasons I am using it at the moment: 1) I have a few of them lying around 2) I have a Tiny84 which I will probably be using (even that is overkill) but I don't have an Eagle library for it.
I was going to use the internal pull-down resistor for ignition_sense, I also figured that D2 won't harm (and won't cost me anything) so any extra protection is worth a squirt.
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