At the moment the full product is a build to order and the reason for that is cost of silicon sitting on the shelf. That's already being considered to become a stocking board and a cut down would be easier to justify stocking especially if we get steady orders. The 4-6 weeks is a standard time we quote and usually if we have parts, which is usual on Spartan-6 based boards, it can be a lot less. It's more a case of not disrupting our assembly line schedule for say 1 board. If we have a 6 week window we can make a nice slot and maybe build a proper batch size at one time. These are all to do with the economics of building boards.
Merrick6 can run stand alone if needed and there are some communication options here if you are not using the PCIe.
If there is a serious interest we could do designs based on our Raggedstone2 and Lamachan2 boards to offer a PCIe board with 4 or 8 XC6SLX150 FPGAs that would come in cheaper per FPGA. That would need some numbers to make this a worthwhile project.
I'm just a guy interested in FPGAs, I don't have the knowledge to understand what chips would be ideal and what not. What I do know is that there are a number of FPGA mining device manufacturers. While they might not be interested in sharing their sales numbers but a few hours of searching on just this forum could give you an idea of a fraction of sales they are achieving. I'm fairly certain the majority of miners have seen the light and realize that FPGAs will eventually price GPUs out of the mining industry. Someone who could deliver a hashing dense FPGA device with an appropriate turn around time could swoop in and snap up orders from the likes of BFL and LargeCoin. I'm not sure what the setup/design costs would be for you guys to design a PCIe card pushing 1-2 GH/s but I'd be thrilled to see another competitor in the manufacturing market.