Today I used my new Dremel the first time and cut a hole into the G5 PSU for a 120mm intake fan. Because the front fan tray will block the two 60mm fan intake holes this should work properly.
Last thursday I was able to solder some extensions for the PSU wiring and am now able to place the 2nd PSU board further away.
Tomorrow I will try to fix the boards to the housing by gluing it with two-component adhesive.
A couple of tips/observations:
1. Make sure you seal the front 60mm fan intakes, so that no air can escape, you want all the air from the 120mm fan to travel over the main PSU board.
2. Make sure you use decent thickness wires for your extension, and at least the same number as the original configuration. There don't appear to be many cables in the pics, is that a low wattage PSU?
3. When you say glue it to the enclosure, you have to be careful that the PSU board is connected to the enclose the same way as in the original enclosure, generally that is with screwed metal standoffs. This is important because the standoffs create an earth circuit with the enclosure. If you glue the standoffs (epoxy is an insulator) then the earth circuit will be broken and the PSU may not function.
4. Lastly the PSU board should have come with a plastic insulator to protect the underside of the PSU board, make sure you use this.
Sorry if you know this already, but they have been several posts ending in failed PSU conversion on this forum.
Kiwi
PS What was your eventual HDD drive bay conversion ? Did inverting the rails on the Lian Li work ?