The full list of steps, and a ton more of photos have been posted in the FrostyTech Forums here. If you want some more detail on how we built this little guy I suggest you stop by an look over the logbook of its construction at some point.

Basically we took a full sized Alpha P125 heatsink and cut off part of the sides to make it short enough to fit on the GPU without knocking over any capacitors, or other components. The base of the Alpha heatsink was lapped to remove any marks caused by drilling in a series of eight holes which would be used to hold the copper plate, and TEC in place.

One or two revisions came and went until we finally found a design which accomplished everything we needed in the best possible way.

Since we are using a surplus TEC removed from an old Swiftech MC1000 there really wasn't much work to be done. The Melcor TEC came prepared with wires, and a Molex power connector. It was literally only a matter of properly positioning the TEC on the base of the heavily modified Alpha heatsink, applying a thin coat of Coolingflow ceramic based thermal compound and then mounting on the copper base plate in place. I tend to prefer this material over Arctic Silver because it has pretty good thermal properties and is easy to clean up.

Another benefit of the ceramic material is that it is non-conductive. The last thing you'd want is to accidentally short out a high-current by whatever freak coincidence, and in any case you really shouldn't use much thermal paste with a TEC anyway. I used a small rubber block to spread out the material to a very thin layer over the entire surface of the TEC.

For this project we decided against potting the TEC with silicon, and instead filled the space between the copper and Alpha heatsink with some rigid blue insulation foam (similar to the kind used in construction of homes). This foam is easily accessible, and we had some lying around so it was an easy decision. The insulation helps keep the heatsink from warming up the copper, and when the GF4TEC is shut down, it also helps keep a lot of the water from getting into the TEC if there was frost.