I'd be very happy to have you look at the freeduino PCB design; your experience with actual commercial kit construction would be very valuable. Right now there are 0603 and slightly older 0805 SMT layouts, and we're
debating whether 1206 is (a) possible and/or (b) necessary and sufficient for amateur construction (from kits or bare boards.) Have Daniel add you to the list of people with access to the pre-publication file area.
ill take a look at it this weekend, i just have to wrap up some other work today..
i think 1206 is -necessary- for hand assembly. 0603 is great for machines but certainly no fun, even for 'experts' like me