While this is from my other thread, I think it makes sense for people reading this thread to learn.
Another thing that shocked me : look at the fan construction. It doesn't take cold air from inside the case at all. it takes cold air from the little hole at the top of the jacks (mic and ear). So when the fan is on, it doesn't make any airflow through the case.
Summary : the chipsets are triggering a fan that doesn't cool them.
I noticed this too.
While the fan is working hard, take out the slim-bay drive/battery and leave it open. Then put your fingers next to the open sli-bay slot. You can feel the system sucking in air, which suggests that when the bay is used, much needed air is having trouble entering. We are talking at opposite ends of the laptop.
I observe air being blown out over the audio jacks, not being sucked in like you two observed. I just took a piece of hair and held it in front of the vent, and it was being blown away from the laptop. I think the way the fan works is it sucks air in from above it (perpendicular to the plane of the blades) and forces it out along the sides (paralell to the plane of the blades). Air is being sucked in from someplace else, perhaps the holes in the front near the speaker?
I've played with cooling overclocked desktops a lot, always with the goal of making the computer as quiet as possible while maximizing performance. I even made a custom water cooling setup once. This is going to be my first crack at laptop cooling...
I'm going to fit some copper foil over the north and south bridge to help cool it like nrj45. However, I'm going to use two separate pieces of copper, one for the northbridge and one for the southbridge as I think it will be simpler to construct (I won't have to make three bends in one long piece of copper, only one bend each on two pieces of copper). The northbridge will cool to the CPU area of the heatsink and the southbridge will cool to the GPU area of the heatsink. I'll post some pictures when I'm finished.
I'm going to upgrade to some arctic silver 5 on the CPU and GPU and use thermal tape on the two bridges. The thermal tape will keep the copper tightly fixed to the bridges. I ordered the copper and thermal compound today, so I should have this done by labor day weekend. Thanks for all the ideas... I would never have thought to do all this on my own.