Glad to see you tried Sentinel's foam board mod, and I'm encouraged by your results.
I'm trying to capture additional fresh air for the CPU intake from a filtered blowhole, while allowing for the "serial" augmentation of fans that John Cinnamon -- Sentinel's inspiration -- posted on his mod. I need to open up my intake duct behind the filter, to draw clean air from inside the case.
I already purchased my $5 foam-board panel, and bought $16 worth of clear Lexan because I wasn't sure with which material I'd be better satisfied.
Here's my minor problem. I want to keep the 120mm blow-hole duct that mates up with the side-panel on one end and the CPU fan on the other. That takes up some space inside the system.
The other minor problem -- these mods all seem to utilize two 80 or 92mm exhaust fans arrayed vertically down the back side of a tower case. In my tower case, I installed them horizontally -- two twin 92's. Therefore, the fan-orientation is perpendicular to the plane of the flat-panel mobo-duct/cover, but I CAN make it work. But once I do, I'm afraid it will be cumbersome to remove the duct anytime I want to diddle with the mobo or fix something.
Anyway, I'm just taking my sweet-assed time with this, as I have with everything. If I'd known about the effectiveness of this type of duct when I started cutting on my recycled-full-tower case a year ago, I would have made a special effort to be more daring about how the fans were installed, or I might have dared to make cuts so the two 92's would instead have been a single 120mm.
But here's an observation. Because my blow-hole duct is isolated, and the blow-hole is filtered with an Ultra filter, I discovered that the new 125 CFM CPU fan I installed was not really pushing 125 CFM -- if you know what I mean -- because of the filter. Sentinel and Cinnamon are absolutely correct -- this is all about balancing air pressures between various intake ports and exhaust ports. I can actually tune down my front intake fans and tune up my exhaust fans, and the throughput of the CPU filtered blowhole increases, giving me a drop of 1 to 2F in the CPU temperature. And that's before I have even started with the foam-board mod, or putting behind-the-filter louvers in my blow-hole duct!!