i didnt follow this plan, but used my own for a 92mm fitting to a pal6035. I used 28 gauge aluminum, i at first thought it might be too flimsy, but once folded, it was more than stiff enough (and pretty damned light).
I would caution to look at supporting the extended HS/F combo, as the extra torque on the zif socket tabs can not be healthy; my HS is clipped on pretty tight to begin with. I dont ever want to have to deal with a broken clip tab. I used a couple of zip-ties to tie the fan up to the bottom of a PS support.
for attaching to the HS, i got some shorter 3mm screws, made the shroud with 8mm^2 tabs that sat on each corner of the HS, drilled a hole in each, and used the shorter 3mm screws (with a locknut, steel washer, and a couple of rubber washers to help isolate any vibration from the fan). finding shorter screws for your HS (which is now a 60mm fans-depth shorter, i think 25mm for mine) is a trick though. you can just cut down your old screws with a hacksaw or dremel. I didn't, in case i needed the 60mm fan remounted.
hope this helps, this is a fun case mod to point out to house guests. Dont forget to paint it, i used a flat black with sealant.
g.
