Hi Dave,
I recently discovered your YouTube channel and have been watching the PSU series. I was excited about being able to by this thing as a kit until I watched the last video about Rev C and saw all those no-lead flat packages. You then confirmed in the comments my heartbreaking concern that in this kit the board would come pre-assembled.
Now, to Aunt May that would be a "kit". But, to the target audience, it's really just of a product with some minor assembly required. If we don't get to solder anything then what's the fun?
I think you should design it as a moderate skill-level SMD based kit. This would allow several options:
A) Machine assembled PCB, enclosure, etc - For Aunt May
B) Unpopulated PCB, loose components, enclosure - A proper kit for your core audience. Even with a healthy repackaging and shipping fees, the 100+ piece discounts you'd get would likely be more cost effective then us going to Digi and purchasing singles.
C) PCB only, and a Digikey scavenger hunt - The PCB is the hard/expensive part of DIY electronics. I may already have many of (well.. a few of) these components. Tracking down parts is half the fun.
D) Design files only - Break out the Ferric Chloride!!
Please think about it. Most of the people who would buy your PSU kit are hobbyist who actually ENJOY building electronics. And we're not all gorilla-fingered idiots; so you don't have to limit your design to strictly through-hole packages. Just please keep it to easily hand solderable parts (0805 skill-level stuff, preferably).
An electronics kit should require a soldering iron and not just a screw driver.
I, along with a great many of you viewers, look forward to being able to buy one of these kits.