I sat with him and went through the Farnell utterly hateful parametric web interface and eventually came up with a couple of options which were very expensive. Only then did I stop and ask what the actual problem was.
There is a single 40mm fan trying to provide cooling for the entire enclosure. When the units are placed horizontally and used intermittently this proves adequate. Unfortunately when the system are arranged vertically in a rack and run at full load continuously they often overheat and have to be restarted. In addition the small high speed fans need replacing frequently as their bearings wore out quickly.
This was obviously causing some issues for the ARM Debian ports which Steve wanted to rectify. After talking the problem through for a while we came to the conclusion we could use much larger 60mm fans to blow air directly through the top of the case onto the cpu heatsink.
Larger fans can be run much more slowly to move a similar volume of air to the smaller 40mm fans which gives a much longer service life.
I acquired a rather large steel hole punch, I chose this tool because it produces a much superior finish to a hole cutter and this project demanded a high level of finish (not to mention I loved having a valid excuse to own and use a huge allen key!)
If we had simply been modifying a single case I would have measured and marked up by hand. With the prospect of altering at least eight I laser cut a template from plywood which Andy Simpkins took great glee in excessively annotating.
Steve and I modified a single system to begin with both to check our alignment and the efficacy of the change. We were pleasantly surprised to discover that hoiby could now repeatedly do kernel compiles with all four cores flat out which was not possible before. The measured CPU temperature, which had previously been around 90°C, did not rise above 40°C
Cambridge Makespace where I am a member to do the modifications.
I broke two 3mm drill bits and dulled a 4mm bit drilling all the holes, Roger Smith was good enough to loan us the use of his "Christmas tree bit" to ream the fan hole out to 16mm so we could thread the hole punch and cut the 60mm fan aperture out.
It has been several months since we did this work and these systems continue to run without issue. To complete the story we can see some graphs courtesy of the DSA munin instance.