Finished...just about.
Well the down time on the gauntlet over the weekend led me to do some work on the folder (don't worry its crunching again now

) and impulse buy a cheap case, as keeping the cards apart was becoming a problem and I needed some fans to prevent overheating.
I started by taking off anything I didn't need, the front fan had a grill in front, some kind of spinny turbine thing, and a bracket behind, all impeading airflow.
I also needed to create a hole in the bottom of the case to get air to the XFX GS. I started of with my rotary tool, after about 15min and 2 snapped blades later I gave up and got out the jig saw. 1 min later I had all the holes cut

.
In the pic above you can see the (awful multi coloured LED) fan is now clear, and there are 2 holes in the base for the XFX. The stock cooler on this card is pretty crap in that it blows hot air back into the case, to divert this outside I've added a piece of white card.
The problem then came with the vortexx neo cooler, when the cards were being held in place properly (ie not leaning apart with no support), the neos' fan was touching the next card and not spinning at all. Lucky I didn't have any load on it and spotted the temp rising before it overheated.
So I've had to go back to the stock XFX cooler which blows air back into the case. Below is the solution I've come up with, the white card now directs hot air from both XFX coolers outside of the case, and the small fan provides air to the inside XFX card. The white card also diverts the air coming in from the main cooler on to the 2 flower cooler cards. (The mass of cable look in the way in the pic but they are actually quite high so plenty of space for the air to flow under them.)
So far so good, temps were looking good, and I also had time to set up the folding clients, with the card shaders at 1850 (I will push them up a bit more once folding again) the ppd / temps are as follows
And that is pretty much it, just need to pick up the network cable from the sorting office and get it back out into the shed.
Performance:
PPD: ~16K
Power comsumption: ~400W
Price of parts:
4 X 8800GS - £90
MSI K9A2 + AMD Athlon 64x2 + 1Gb RAM - £85
CIT case - £25
30m RJ45 - £5
All other parts salvaged from old systems
Parts - £205
P&P on parts - £15
Total £220
Thanks for reading and all your help and suggestions
