Suggestion
Turn the existing 120 around, mount another 120 on the other side of the rad blowing towards the case, then you got yourself a push/pull grabbing cool air from outside the case. Then you can turn the 80mm around and have it exhaust out the front
This would be one way to do it. Another would be to do something like this (arrows pointing in direction of airflow):
fan -> H50 -> shroud -> fan -> fanguard
This way he could keep the 80mm in front, which I think he only has provision for mounting one, and keep the airflow direction exausting outside of the case. But, since he's running a lil box for his system he could even reverse the fans as well to see how that works but the above configuration is pretty much the one most seem to get the maximum bang out of.
For the video card he could easily I think fit up a little duct in the side that would mate up to the intake hole so that it pulls in cool air from the outside as well. But, from the looks of things it probably would mess up the overall look of the system so it really depends I guess.
Did the rough cut with a tin snips, mounts up well, I think this will work!
Have to cut some of the black cover too, so I am able to put it on with the rad.
VERY nice! I really like how clean things look on the inside which I'm pretty surprised at since most mini boxes like that one are an absolute nightmare to get looking tidy.
Put together, running a buch of wprime to get things warm. It's working very well so far.
Fan is blowing out. I don't really care if this is the best setup for the fans, It's clean and looks good and it works. The AII x4 is pretty cool to begin with. It's a HTPC, clean and looking good is important. I'll post some before and after temps in a moment.
You should consider trying the above fan configuration since it would still look pretty decent just would stick out a bit more in the back. But, failing that, the temps you are getting are pretty impressive so I could understand if you wanted to keep things as they were.
*whistle* Wow, that's a NICE job you did getting that H50 in there like that and looking tidy to boot! What are your temps like with that box since I'm really curious considering how small it is.