> Alternative to Mrs Eaves..

'( John ) Baskerville', by František Štorm..

> The criteria is an easy-to-read, approachable, friendly, warm, smart but non-intimidating atypical font..

'RePublic', by Tomáš Brousil / Suitcase..
'Delicato', by Stefan Hattenbach / MacRhino..

easy-to-read, approachable, friendly, warm, smart but non-intimidating atypical font:

Californian, the dress jeans of text fonts.

Californian is a great font. However I would say it's dress jean with a tucked long-sleeved dress shirt. I'm looking for a jeans and short sleeved golf shirt with a hint of flannel.

Client is a middle aged engineer?

Actually the target audience is more feminen. I am not sure what the equivalant outfit would be.

I’m looking for a jeans and short sleeved golf shirt with a hint of flannel.

well that would be Goudy Oldstyle, but you've nixed that already. Let me think...

I think Andulka has some of the features you're looking for, maybe a bit too sophisticated for what you're looking for (if i'm reading you right).
Have you looked at Paperback? I think that has all the qualities you've said you're looking for. I'll try to come up with some others...

Dude, he said "more condensed".
Some of you guys are falling for Font Of The Week Syndrome.

hhp

maybe, but is it hard to be more condensed than mrs eaves, brah?

also, i think the more condensed you get the less "approachable, friendly, warm" you get. but maybe that's just my feelings.

It's small on the body, not condensed. In fact the x-height region is pretty wide. All this means that if you equivalence apparent size with a font with a larger x-height, the set-width for Mrs Eaves will probably be greater.

I'm thinking Octavian, or Stone's Print.

hhp

Stone Print and Paperback are great suggestions. Times Europa is pretty good too. We're definately on the right track.

Is there anything that is more handmade looking or letterpress like?

Have you considered Whitman? Not handmade or letterpress-like, but certainly "easy-to-read, approachable, friendly, warm, smart but non-intimidating":

http://www.fontbureau.com/fonts/Whitman