I found a pile of stuff on RS online - free postage, so bought most components from them. The Molex pico EZmate and Lite-trap connectors look good. I found the IRFS7430-7PPbf there as well - Rds on at 6v, 0.9milliohm. Lots of goodies - SMD 6A resettable fuses.
This project will use some through hole and some SMD - passive components, size 1206, which is about as small as I want to manage. The ICs are D2PAK with various lead counts. Happily I was also able to find 1206 100nh wire wound inductors. I was contemplating surface mounting a Mega32U4 IC, but when adding all the peripheries, USB and so on fixing a Teensy 2.0 to the board takes up marginally little more space - not worth the effort.
http://au.rs-online.com/web/
I forgot the 5v connection in the schematic - all fixed now.