I am not sure what Mundorf would charge for a small batch of custom caps, but the idea of having a group buy has been discussed as an option. I am wondering what something like this would cost. When I will have some time I will call Mundorf and report with the response. The concern of some AK'ers, and mine for that matter, was that it will be prohibitively expensive, even as a group buy.
As far as the other options, the dual cap cans would require mods to the circuit board since they are too tall for any use of a daughter board.
I am still curious to find out Avionic's solution. He stated in one of the posts that he is working on a solution but has not yet revealed additional details.
As far as using banks of 10,000uf caps, you stated that there may be an issue with the rush in current. Now that you have looked at schematic and the design of the psu, do you believe that is still the case. Wouldn't the esr of the multiple caps be beneficial?
The reason I still mention this idea is that a bunch of 10,000uf will physically fit on a daughter board and no modifications to the main board would be necessary. Let's say that some manufacturer decides to start making the original cap sizes in a few years, or the group buy idea turns out to be financially feasible, there is no real problem yanking the daughter board out later on, and replace it with the original size cans.