What I'm trying to do is make essentially the "silent PC". I want to leave it on all of the time in suspend mode and literally not know if it's on or off except by looking at the status lights.
My computer is not overclocked so I don't have to worry about temperature much. I bought a quiet power supply, replaced the chipset and video fans with extra quiet ones and now, when I unplug the CPU fan while it's running, I literally can't tell if my computer is on or not - which is the goal that I am seeking. So I think that all that is left is to replace, or to quiet, the CPU fan and I'm done.
The retail fan is not particularly loud, but you can hear it so I'm going to come up with something. I think using a switch or a rheostat and a large wattage resistor to cut the voltage to the CPU fan by about a 1/3 should do the trick. Or I'll save myself some time and just buy the solution from Thermatake.
<< Keeps my non-overclocked 2.2Ghz around 32C under full load. >>
Wow. That is truly impressive. I have a non-overclocked 2GHz Northwood and it's running about 50C under load currently (39C case temperature - both as measured using the thermal monitoring program from MSI that came with my motherboard).