Ti4200 for $20? Where at...sounds like the perfect present for family members!!! LOL
Hopefully your videocard wasn't shipped with the new "meatgrinder" antiterror service. I've seen some pretty mangled boxes of late, I suspect my local courier is at the brink of going postal. If there's ever a shortage of expensive looking packages to abuse he'll likely flip out and the last I'll hear of him will be on the 10 o'clock news.
On a more serious note, the first batch of copper heatsinks has just been ordered. The dimensions will be roughly (based on final CAM programming) 95x75x25mm. The heatsink will be a solid copper skived plate fin array piece with a diamond lapped base. (Time to raid the 3M catalog again)
Keeping the already competent stock memory cooling is the best option, so this heatsink will occupy the region above, around, and to the left of the GPU, fitting snugly within the embrace of the stock memory heatsink.
Cooling will be supplied either by a 60mm blower, with exhaust facing towards the back of the case, or by a 80x15mm dual ball bearing fan. Either setup will likely include a 3 step PCI bracket mount fanbus.
For Ultra and GTO users - if I stick to the blower setup with the rear exhaust path, I'll order a bunch of 6800 Dual DVI/S-video single slot PCI brackets to allow for such a retrofit.
This new revision will not occupy more than 2 PCI slots.
Oh, on a side note, the copper heatsink I am spec'ing can dissipate 110W while maintaining a core temperature of 75C. Can any one say passive cooling option?
(@40C Ambient)
The active cooling options:
-60mm blower for rear exhaust (5-15CFM/30-50db)
-80mm fan for direct convection (20-45CFM user selectable/20-40db)