Here's what the closed case looks like. Every inlet is taped except for a little hole on the front which sucks air over the hard drive and the gray duct inlet on the side. Since this works, I'll tape the front from the inside so it looks cleaner
Here's the inside of the case, showing the zalman heatsink with fan removed. I try to keep things pretty clean.
I bent a piece of cardstock to shape and taped it in place here. This forces the most air through the fins, rather than through the large holes on the sides. Testing proved this helps considerably.
Here is a view through the hole in the side of the case. You can see the heatsink lines up perfectly.
This cover goes over the hole and holds the duct from the inside as well. Airflow and cooling are slightly better without this, but it looks more trimmed and is still acceptable with this cover.
This is an inside view of what the duct looks like. It extends an inch or two, but the case side can not be attached with the duct extended. It hits the fins of the heatsink. So I tied a piece of string accross the duct, and bent a hanger so that I can stick it through the gray plastic cover and push on the string, therefore extending the duct all the way into the heatsink AFTER the side is on.
Here is how the duct sits inside the heatsink. It seems to work best when all the way down, even though the outer fins don't get direct airflow. Maybe some drilled holes will be a future mod.
This one is a view through the gray duct cover. You can sort of see that the duct goes inside of the heatsink.
Finally, here are my temps according to intel active monitor. This is after running CPU burn for an hour or two while typing this, and running all the photos through photoshop, with pefect stability.