1. Easy to add 2.5mm to the edges to get 105mm x 105mm around is best suggestion for those needing manufacturing clearance.
Not sure I like this idea. Lots of cheap board places offer fixed sizes, once we exceed 10x10 the price will go up.
eg. http://imall.iteadstudio.com/open-pcb/pcb-prototyping/im120418009.html
Actually I think it would be smart to fund a run of two layer sample boards so that the assembly can be tested early. This would allow us to build mechanical prototypes to check the heatsink attachement etc. Bkk send me a PM if you want me to help with this.