My Xbox has been together, kind of, but ran at 62 degrees. Shut down is at 65!!! I put the lid on and took it into my workshop. I placed it on the bench in front of some burning leaves. The fan was taking in the smoke but not a lot was coming out of the sides. There is too much stuff in the way internally blocking the air flow route through the box. The problem I have is that there are no alternative positions for the 'extras'. Whereas a V1.0 box has a smaller heatsink on the GPU, mine is huge and restricts the available space considerably. I have concluded that my Xbox will be housed in a custom metal case, yet to be sourced. It will be the same width as Hi-Fi so there will be tons of space inside. I will be installing a 5-8 port switcher internally as well.
The decision has been made based on three factors.
1 It gets way to hot and will fail soon after completeion.
2 I had to remove the sockets from the X2VGA to position it under the DVD drive. Those woth Thompson or Philips drives may not be able to do this because of the bulge underneath. The Samsung I have is flat.
3 A Hi-Fi width case will look cool, provide more space and mean more people can have a go without messing up a stock case. The case I choose will be readily available and need no special tools to configure. NO part of the XBOX PCB or interanl components will need to be modified. The AVIP could remain on the mobo but have a retail lead plugged in to take the signals out to the respective sockets. If someone wants to return there box to normal they can.
More as it happens.
For those who feel that a recase is cheating, be aware of the thermal issues all the extra stuff brings. If you want to stuff your box with high CFM fans, knock yourself out. I am disappointed but want reliability as well as the features.