Zephyr is back!
In January 2007, my stock PSU failed a second time after I had replaced several capacitors after the first failure a year ago. I was down for about 2.5 months. I replaced the PSU with the 60W Morex unit and added an exhaust fan driven by the +12V output. I primarily followed these directions http://rev-a-dead-roku-club.blogspot.com/ --- although I did make some variations to the fan installation since I wanted the air to flow from bottom to top in my rack.
Fan details: I covered the side vents and former bottom vent with foil duct tape. I drilled air intake holes in the bottom of the unit, on the far side opposite the PSU location, surrounding the location where the serial number decal is. I mounted the fan aside the PSU, using some of the holes that had formerly been for the bottom vent. I mounted Radio Shack 12V, 40mm fan (273-240) on aluminum spacers, and drilled a 1.25 inch hole in the top cover to act as an exhaust port. I chose 0.75 inch spacers and added some washers so as the spacers and washers hold the fan up from the floor of the Photobridge and as near the top of the unit as possible. The result: 68 degF ambient air taken from the bottom right of the unit (oriented looking at the front) is exhausted at the left top at 79.5 degF.
One bit of irony: the first Morex unit that I received was dead on arrival. Logic Supply had wonderful customer service to replace the unit. No problems with it.
I will also comment that the remote control response is much snappier with the new PSU.
-zephyr