CrossRoads:
...Ok, I reread - you want the connectors to be accessible so you plug in direcytly.
I would go with soldering to the bottom of the board at the jack itself then, the metal the jack pin will keep all that current from having to go thru the board traces as well.
Good idea, I think I'll do the careful soldering. ...about the anodized aluminum box-enclosure- it doesn't matter that it will touch the USB casing. ...and the DC jack is plastic, so it won't be touching...