I bought one of these: http://www.ebay.co.uk/itm/Musical-Electric-Guitar-FX-Tones-Effect-Wah-Wah-Pedal-/180692952764?pt=LH_DefaultDomain_3&hash=item2a1223a6bc for £18.
Its actually not a bad wah - but its a plastic enclosure, but the plan was to try it in that. But I just don't think I can fit the beast in (which my wife says is usually not a problem).
So, I had been thinking about the expression pedal route. Unlike you Jim though, I didn't think far enough ahead and hadn't considered the travel in an expression pedal.
When Greg Convington was selling his version, he discarded the manual mode and just had them wired for auto. That's the way Brian May used his, but to me, it seems a bit wasteful and taking something away.
So, I think I'm going to explore the expression pedal route. Its the best of both worlds. Would it be possible to switch between manual and auto by simply detecting whether a jack has been inserted? If not, keeping the switch wouldn't hurt. I'm not sure as how to wire it, but that's why god invented Google.
Just another note, my thumb is broken and I can barely hold my pick so please don't judge my playing. I wanted to re-record this as a comparison, which I recorded with the Digitech Brian May thing, but that's a few weeks away when I can take off this splint. https://soundcloud.com/nickbungus/queen-medley-with-vocals