barebone ide / airflow problems

Anyone had experiences with barebones, and if so, what to do with the airflow problem?
I work mostly with Shuttle - series barebones, end the problem here is that the back end of the harddisk is about 1 to 2 inches above the processor heatsink / fan (depending on type, some have a regular fan, other have heatpipes to the back).

Regular flatcables have to be or twisted completely to the side, or positioned right above the processor, resulting in a smell of burned rubber. (yum.)

Rounded cables can help for a while, but the few tiny loose cables tend to heat even faster than a flat cable, resuting in data loss and errors...

I have to build about 30 barebone systems / month, and get about 12 defective systems per month back...

Are there any specially shielded IDE cables on the market, or any other solutons would be higly appreciated.
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  1. why dont you just use a real case to build comps

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  2. Sounds like you are not using fully enclosed rounded cables. <A HREF="http://www.directron.com/silveride.html" target="_new">Some</A> of them have the individual wires exposed at the connector, while some are sleeved along the entire length of the cable. Like <A HREF="http://www.directron.com/idea26.html" target="_new">this one</A>. Perhaps just that extra bit of shielding would be enough. Could be worth a try.
    There are such products as heat resistant tubing, but I have only seen it sold in bulk, for industrial uses. You might even be able to get away with just taping a piece of insulating foam or some other material on the underside of the cable. Does it have to be pretty?

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  3. Yes, he could even put junk in a real case, and have a similar system without those problems.

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