A bit different from your regular programme...how to fit a huge ThermalTake 80mm cooler to a tightly packed Socket370 motherboard.
The reason: my original small cooler is a VERY loose fit over the CPU, its heatsink gets crazy hot and the CPU measures 70°C or more when working, 60°C or more when booting, and rarely below 46°C at idle.
The problem: capacitors right next to the CPU socket, allowing no room for the overhang of the ThermalTake 80mm cooler.
The solution: build a spacer the size of the socket to provide enough height to clear the capacitors with the 80mm part.
The challenge: all mods must be reversible. Everything needs to be buildable with the machines I have available here.
Here we go!
The idea: take some 25mm thick aluminium stock and place it between the copper part and the aluminum heatsink (here shown in the wrong order as I hadn't done the disassembly yet).

Cut the stock to length with a hand saw (pfffffff) and make true with a hand file. Next, measure where the slot for the clamp needs to be. 25mm height is on the low side for the clamp mechanism, but doable.

Milled out the slot with a manual lathe. No measurement on the lathe itself, so a lot of measuring in between. Here the slot hasn't been cleaned/made true yet.

The clamp also needs a perpendicular slot to fixate its hinge point. This was a very challenging plunge cut with a tiny end mill. It would have been easier to do this step before the main clamp slot, but that would require quite exact measuring and milling.

Now I needed to replace the original short bolts with long ones to take the extra 25mm. I have those, but not the countersunk kind. So I modified them on the lathe. I switched to drill press + Dremel for this task later, as I was bending too many bolts on the lathe.

Now indicate and center punch the 4 holes VERY precisely: I'll drill them 3.5mm for M3 bolts.

Done!

The result after a lot of thermal paste:


This contraption installed quite easily on the CPU. I had measured the clamp slot very precisely to assure I'd end up with the same clamp pressure as original. It installed easily, far better than some horror stories in reviews. It's also not too loose; nicely fixed in place without crushing the CPU at all.
The results are astonishing! Partially this will be because the heatsink surface is huge compared to the original, as is the fan. Partially the fact that there is proper contact with the CPU will also help quite a bit. Anyway, 30°C during boot, 28°C idle and very shortly after running two 3DMarks. Ice ice baby!
In total this setup is quite heavy, but as long as the PC is stationary I don't think the motherboard cares at all. I wouldn't ship the PC with this aluminum throne installed, but I'd use it like this for decades without worrying. The bending moment is quite low as the heaviest part is closest to the motherboard.