I placed the order for the power supply, I'll play with it. According to Aibohphobia's video, the width of video card + PCIe board is about 56mm, so the overall front size of the enclosure would be around 95mm x 150mm, which is ugly I have to admit, but there is one advantage, I can install a standard 92mm front fan like Noctua NF-A9x14. Ideally I would rather have it 12 mm narrower and use a 80mm fan instead. An engineer from Fairchild was able to build a 300W 12V power supply as thin as 18mm in 2010 (
https://www.slideshare.net/SteveMap...low-profile-acdc-powersmappus-may-2010edit-sm). I already found some products at 20mm (but over 300mm in length), my idea is, looking beyond the PC parts.
UPDATE: Here is one (
http://www.mouser.com/ds/2/281/mvac400-463546.pdf), 400W with active PFC, 1% ripple, 30x76.2x127. Install it back to back to the video card the width is about 70mm, side by side with the Thunderbolt board the total length is around 240mm, the height is totally fit, give some room on each side the total size is still manageable. A little pricey at $170.
EDIT: I was a little over-optimistic about Murata MVAC400, it's open-frame so the PS needs standoffs too, that will bring the overall width of PS+video card to 77.95mm, so it's the right dimension to fit in a 80mm front fan. Including the bracket, Zotac 1080 Mini is about 227mm in length, so 240mm of the PS+Thunderbolt board is close to a perfect match. There are 18mm space behind the Thunderbolt board will be wasted, maybe I could squeeze a Schuter 2563 C6 plug over there (19mm if rotate 90 deg). I guess it's hard to find anything better than this combination, I'll start the actual layout when I have time.
EDIT 2: I could think straight. This $170 power supply measured at 37.96x76x127, and it's open-frame and passive cooling, isn't it the same if mini-ITX PS removed the chassis and cooling? Now I'm back to the origin.