So I've addressed the 58mm width with Larry at HDPlex and am hoping he can narrow the unit by 1mm so fitment isn't an issue on the S4M. Worst case scenario is that you'll need to sand 1/2 millimetre off either side to get a fit.
As far as bottom mounting the unit goes, you can quite easily use an adhesive of your choosing to anchor the unit. I personally love 3M's 8810 tissue tape as it also acts to conduct heat from the PSU to the chassis, I believe the mounting points are there for the HDPlex case and not specifically for the S4M.
As far as the C8 goes, it is a simple connector with no EMI filter as far as I know. This means that yes you would be running a 400W AC-DC unit ungrounded.
1. 0.5mm of metal is a lot of metal to sand. It'll be a pain.
2. C8 is designed for 2.5A. Which comes to two issues:
- This means for NA you're limited to 280W (120*2.5*.94(efficiency))
- You should not be running a un-grounded unit unless there is a low chance of fault. This means things that are insulated are okay (external bricks) but chassis mounted means it is conductive to the case, and so the user.