I just did a little reading on the case mod (blowhole) and it looks relatively simple. Problem is that I will need to do a mockup once I get the power supply and use an optical drive from another PC so I can get an accurate measurement.
Are you going lap(polish) the copper part? You can polish with SSR2.5 then follow up ssr2 or you wet sand it the outcome look like a mirror..... It work like a charm too. I did few of them in the past.
I lapped the HSF on a previous build, but didnt notice a huge cooling difference (maybe 1 or 2 degrees, but that could be attributed to reapplying the thermal paste).
Ive also heard that Thermaltake blocks are nice enough you dont need to bother. Granted, they arent mirror finish, but the one I received was plenty flat enough to provide good cooling.
But I suppose any way to use car care products on a computer would definitely show you are an Autopian!
Update: The grille I want for my blowholes won't be in until May. I am going to continue the build regardless. Plus, I have a new problem with my old computer. It seems that the IDE controllers went out last night on the mobo and I am trying to debate between buying an IDE controller card or getting another mobo.
One thing I learned about doing these builds is that components change during the process. I have changed what I am looking at for hard drives. I am now looking at a 500 GB Seagate and 2 750 GB Seagates. In addition, I am going for a 7900GT since I haven't heard from the person with the 7800.
I just remembered that I changed the RAM as well. I am going for G.skill DDR 400.
Not one to hide my light under a bushell, the linky in my profile might be useful for noobs to the PC building arena. (not a business, just an online hobby site)
Prometheus: The Opterons are the best bang for the buck in terms of processors now. Many people who build AMD boxes use them and they are very stable even when overclocked.
As for the OS, I am going to install Windows XP Pro. The next build I plan may have Vista.
I always just thought the Opterons were a little too expensive for my taste, but they are nice chips. That should work out great for you. If it were me though, I'd dual boot with a tweaked linux distro