Tom's Hardware: Topic Laptop transformer heat issues
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Long time reader, first time caller 
Acer travelmate 2420 laptop external transformer get's scorching hot to the touch, and we've had to replace several (3) of them....figured it's gotta be heat related.
Any cooling solutions (besides dry ice) out there for transformers? The laptop itself is does just fine until the external power supply craps out and the batteries drain. 
I'll take my answer off the air. 
1.) Go to your local Home Depot with the dimensions of your transformer, get a piece of plate aluminum.
2.) Get a hand brake, or take it to a metal shop.
3.) Bend your AL piece into a the shape of the transformer.
4.) Use any number of methods to secure it into this shape.
5.) SLide your transformer in with heat side up.
6.) Get Artic Silver Thermal Adhesive (available at NewEgg), and Aluminum heatsink material link
7.) Bond the heatsinks to the sides and top.
8.) Whole oreal probably cost you about $25
Thats passive cooling, but it may be enough.
Thanks! That's what I like about this site, ask a real question, get a real answer.
Now if you really want to get crazy you can go with an active cooling system and implement something like this...
Fan enclosure
If you have an old power inverter that is already dead, you can send it to me and I will machine you an enclosure for it for say $75-$100. Solid aluminum (not some 1/16" thick plate) fluting cut into it (not bonded on).. pretty much beyond sweet. I love this stuff 
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