Ed,
Yes, I think it should fit on 10x15cm, although I also am making space for the GPS, RTC and Motion detection boards as well so that I can do my planned upgrades next year.
However the free version is limited to 10 x 8 cm and was constantly reporting everything did not fit. I would think that if I got aggressive with it I could have made much better use of the room but I want to put the components on first and then optimise rather than fight for every component.
What connectors would you recommend? I think I have a choice between putting headers on the PCB and the connectors on the case or connectors direct on the PCB. The disadvantge of the first is that I would have to make up wiring within the case and this is quite an effort. A couple of other designs I have seen use PCB mount RJ45 connections and then ethernet cables for the remote sensors, this makes the cable cheap and off the shelf?
I will have 3 x Sensor and 3 x Battery inputs. I have also thought of 3.5mm jacks for the sensors and small Molex for the batteries?
Martin