Well a quick update here. After sleeping on it and then revisiting the PSU, I feel better. Sudds has been helping me think through the PSU setup, and I'm becoming more confident that I can get it all working and keep it cool at the same time.
So here is the PSU removed from it's housing and the back panel cut so I could remove the switch and power connector.
A closeup of the new power connector and the old. I really want to use the grey, so I need to find a way to mate these two, and I think I've found a solution. Unfortunately the part I need won't arrive for another week, so that step will have to wait.
My original plan was to re-use the bottom plat of the OCZ PSU that has the PCB mounts on it. I would just attach the PCB to the bottom plate like it comes normally, and then attach that plate to the inside of the Apple PSU housing. However, (Sudds) and I are not sure it would give proper grounding to the PSU chassis, so my new plan is to remove the standoffs and then solder them to the Apple PSU enclosure. Either way, here was my lines drawn out to cut the bottom plate out, but I won't be doing that any longer. In a project like this, you have to adapt, and this is an example of that. Thought it would be worth mentioning and showing.
Here's the PSU with the connector and switch free, and placed inside the Apple enclosure. As you can see, I'm going to place the PSU sideways. The reason for this is because the modular mounting bracket in the front of my PSU is soldered pretty strongly to the board and will not move. My fear is that this would act as a wall/barrier to the air that the front fans would be pushing in it's direction. To avoid this, I'll place the PSU sideways. It will be a tight fit with the connectors on the PSU, but I could always cut out the side of the PSU enclosure if I really needed to, as there's actually room on that side of the PSU when it's inside the case.
I'll want to make those holes a little bit bigger so that I can fit more cables through them should I need to.
Okay, on to something different to give myself a break from the PSU. I spent the better part of the afternoon searching for a spray paint to match the grey of the internal plastic in the G5, such as the fans. I finally ran across a primer that I thought would do. I'll post up a picture of the can later if anyone is interested. Anyways, did a real quick test, and I'm pleased with the results. I only did a strip of paint on one of the fans just to give myself an idea. Of course it won't be identical, but the idea is to get it close so that it doesn't stand out. Here's a few pics.
Well, that's it for now. Time to head back to the garage for some more cutting...
