A test with a diagonal strap overheated on 4k 24fps, so it's more effective with the fan right on top of the CPU.  Indoor use definitely requires a bigger fan.

A 50mm 1.2W fan continued overheating anywhere above 4k 4:3 24fps despite the camera feeling nominal.  The SIL pad may no longer be making good contact since the teardown.  These pancake fans are notorious for breaking.  The lion kingdom once had many & they all broke.

Ripped off another piece of plastic that was obstructing the heat sink.  Also tried the labs firmware.  It still overheated above 4k 4:3 24fps, though endurance was subjectively higher.  

4k 16:9 24fps burns 5.5W

4k 4:3 3fps burns 6W

4k 4:3 24fps burns 6W. 

2.7k 16:9 60fps burns 6.5W

2.7k 4:3 50fps burns 6.5W

4k 4:3 30fps burns 7W. 

2.7k 4:3 60fps burns 7W.

4k 8:7 24fps burns 8W. 

4k 4:3 50fps burns 8.5W

4k 16:9 60fps burns 8.5W.

4k 8:7 30fps burns 9W.

4k 4:3 60fps burns 9.5W.

5.3k 60fps burns 10W.  

So 4k 16:9 24fps is the lowest this one goes.  The labs firmware doesn't enable any other modes.

The PLA clamps can't get it perfectly flush.  A home improvement clamp made it more flush but didn't improve the overheating.  Other ideas are buying a thicker SIL pad for a lot of money, trying adhesive pads, paste.

The included SIL pad is not reusable once it comes off.

The next step was a stack of heat conductive tape.  It had to be stacked quite high to make any contact with the heat sink.  The blue putty had to come off.  A + symbol on the heat sink indicated it was making some contact.  This appeared to get it up to the 8W modes before it died.

The grounding sponge & its adhesive tape might also be interfering & have to come off.  The heat sink was basically designed too far from the CPU.  This could be a source of a lot of manufacturing variability, allowing some units to work & some to not.  Thoughts turned to reducing the distance by sticking a piece of aluminum on the heat sink or grinding the case down.  Grinding the case down would increase the pushback from the flex cables.

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The 11 mini with dummy battery, heatsink clamp, & no fan is 89g.  The 7 with dummy battery is 85g.  In the spectator economy, there is no knowing the final weight of something until experimenting.  The next step is mounting it on the robot & seeing how it does outside without a fan.

The pawheld portable would need at least a 5A 7.2V battery.  Maybe there could be a solar panel hat.

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It needs a 3rd enclosure for keeping the heat sink attached in storage.