Minor update:
After driving back from Ashland (Oregon) to Los Angeles in a record heat 2 weeks ago (with no a/c!), I think I can safely say that I've tackled the overheating trunk PC issue. The 'secret' is a super high-flow delta fan, as mentioned earlier in this thread. CPU temps stay around 45c - much better than the 80c or more I've experienced in the past! In fact, I've restored the core voltage for the CPU from 1.2v back to its default around 1.5, to see if it still survives.
Interestingly enough, when I stopped for gas, after starting up again, the audio amp wouldn't power back on (although the PC did), presumably due to overheating. I figure that once I stopped moving, airflow ceased, allowing the heat to build up. After travelling down the road for a couple of minutes, I turned everything back on and all was fine.
While the carpc hasn't changed all that much lately, for completeness I might as well mention a few things not listed thus far in this thread. Probably the coolest is the ValentineOne USB adapter (V1VD) that blanks out my V1 unit by connecting to the remote display port, and displays a pop-up HUD on my NavPod (talked about in some other threads). Configurable audio alerts are played through the PC's sound card and out the main speaker system, but I find the audio from the V1 unit is easier to hear, dynamically adjust, and more 'alerting'.
I finally got around to putting some vinyl on the particle board covering the PC so the install looks a bit cleaner. I think carpet would look better, but I used what I had laying around. I've got an extra Acura logo (think newer center tail-light), which I think might look interesting on the panel. I also think my 2 channel RF amp should be changed to a 4 channel amp with a smaller footprint.
I installed an external slot-loading DVD-R drive into the pocket of a JDM Map holder (the top pouch holds the beefy service manual), powered off the inverter located under the driver's seat (manually switched on). I ran a seperate 5V line to the 7-port cabin-mounted USB hub to reduce device disconnection issues (there are still some occasionally, fixed with a quick reboot). The hub is tucked inside the crevice in the panel behind the driver's left side - there's an amazing amount of space there! I hardly use the DVD drive but I figured it's good to have optical capabilities. The momentary switch that used to control the garage door opener is now connected to the power-switch of the PC, to enable manual power control of the PC during flight (it sucks to have to pull over and go into the trunk to reboot!). In theory this 5v line could power the DVD drive as well, but I'm ok having it manually switched for now.
I keep a flexible ps/2 keyboard stuffed behind one of the trunk panels, just in case something goes wrong, since neither the USB or Bluetooth keyboards work during Windows' pre-gui bootup.
I'm not sure what else to do at this point, but that's probably just as well.. I'm awaiting the new zero-loss Zetoolman sub to replace my dope 10" original Z, as well as eagerly anticipating fixing my A/C and installing the white 02+ wheels I bought from Vance
-Josh