Is this the original block?

http://www.dangerden.com/...l-i7-nehalem-1366.html

AGAIN, why doesn't this have a BR yet?!

Right, 80mm.  I was thinking 90 for some reason. 
 
I was also thinking blind & tapped hole for the block to mount it to the motherboard, but might be a pain in the rear to take apart, but may look better.  So long as you can get to the underside of the block-it shouldn't be a problem.  
 
When you say adding blind holes inside for surface area of water contact, you don't mean to bolt down right?  I was going to ask if you wanted to have some extrusions or anything done to the inside of it.  Could probably chew some material out with an 0.125 end mill or something.
 
One thing about my pdf, it was different from your original.  I just mated the radius of the 2.75" arc, tangent to the .2" radius of each end.  I think you had a .375" radius on each side prior to the .2" radius ends.

You know, I just realized that I am an idiot.  I was trying to get the dimensions when it hit me, I don't need them.  You did it already.  I need the tool path, which I just figured out:

The tool path is the yellow line, and those small radius (plural-radii?) are highlighted in red.  Mission planning is complete.

The hard part is the outside.  As long as I get the coordinate system of the holes, thats all that matters.  The bottom left corner should be X0 Y0
You get me the hole coordinates, and I will get the outer shell. outline with 3/8" end mill.  (unless you wanna give your cam program a crack at that)

just the coordinates for the centers.  I'll write the code for that (easy as anything) I will have to change drill bits so that will be about the extent of that operation.  Then bolt it through the existing bolt holes I just drilled, then cut out the shell.

thanks man. I crashed and burned about 1am this morning without quite getting to the cam.
 
so here is the test block. no leaks!
 

give me a min and I will e-mail them to you

Looks very good and I can only imagine how nice it will look in the sandblasted copper.

Indeed I just do not have the bottoms to get only the tops made.  These tops would look great with the motherboard block, but I would need to figure out the bottom design.

so a solution to the bottom part would be for us to put together a bulk buy from dd. If you are interested in this aproach then I can contact them and see if they will sell us just the bases. I would be willing to bet that even with the purchase nate could get the total block out the door for a very reasonable price for a custom block.
 
now on the temps with this design. I am noticing a consistant 7-15 degree lower temp than with air. I am waiting for the room ambient to reach similar to last night when i benched with air. and this is with the acrylic test piece mounted quickly on a used base that has some scratches on it, and crappy cheep paste. I would be willing to bet that with a new lapped bottom and good tm seat job, that the temps will stay consistantly comparable to whatever block you want to pit it against.
 
I will post my benchmarks for this test setup on a single 5603 overclocked to 12x200 in the morning.

That sure is a very nice design.

I am so excited to get mine Gratuitous.  Cannot wait to put them on the SR-2 and get it under water.  I just need to order the Danger Den blocks to get them here and ready to go.

I am waiting to get the tops and some foam blocks like with the EVGA foam.

not bad for a scrap chunk of 1/2" chunk of aluminum.