well iv finished, rebuild number 2 and its a lot better.
totally gutted the thing and started from scratch, managed to do a pretty good job bar the odd wire.
swapped the front standard fan for a vantec stealth one and put the rear standard one on 7v instead of 12v also put the zalman cooler on my 6800GT on 7v too. its pretty quiet now, prob about the same maybe a bit quieter then the P160
Temp wise its now running the same as the 160 too, the cable tidy exorcise knocked around 5-7 degrees off so well worth it.
things didnt go totally without hitch though. all the faffing with the sata cables led to one of the platic mobo sata guides to snap, still works though. oh and i managed to get my finger stuck in the fan
one of the blades flew off nearly taking my finger with it
oh well, its all good now, and the design is even growing on me, the hard drive bay is still the week spot, they are defo a lot louder then in the 160, going to put some rubber mounts in when i can be bothered. wont be for a while though as the missus is getting sick of me sat in the computer room messing about for hours on end.
and haribo, cheers for the tip, pulled out the wire from the 3 pin and moved it over one. worked a treat, all LEDs working now