BOM is now in the "Files" section with links, will be adding to it as I get some sorted out (the keyboard)
The size could be reduced by at least a third if we remove the plugs and jacks entirely in favor of soldering directly to the PCBs, but it then requires quite a bit of delicate work with any mistakes being rather costly. I choose to just remove the top two USB jacks (carefully) with nippers.
I rather keep the project easy and have it be a bit thicker. It's still plausible because there are makeup palettes with stackable trays: http://www.sephora.com/color-wonderland-eyeshadow-palette-P412573 (the small makeup you might have seen in a purse are compacts, different thing).
Using the Pi Zero is also an option but processing power and usability
would take a significant hit. The Raspberry Pi 3 is, for most purposes a
fully functional computer and generally as quick as a low end laptop
for any reasonable tasks. I didn't really want to sacrifice that.
The Raspberry Pi 3 has on board WiFi but in order to do wireless
Penetration Testing a card must be able to go into monitor mode and do
packet injections- the WiFi chip in the Pi cant do this. So I'm using a
RT3070 compatible adapter.