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I also have a ~5yo sunbeam that was still working fine when pulled. It is the ooollldddd 4ch version. I also had it connected to huge 38mm thick Delta SHE fans, and the system was kept on 24/7.

An h70 will keep an overclocked 7970 under 55c full load, and they can be found for under 50 bucks used. Keep in mind the 79x cards have a recessed core, so besides the bracket/zipties you also need ramsinks and a way to cool the VRMS. I actually cut off the bottom portion of the stock cooler...

I got 5-6c swapping the TIM on my 7970, and I only used some very old AS Ceramique I had in my junk drawer - not even the revised Ceramique 2, it was the original formula that was all I had lying around. Barely a step above the cheap generic Radio Shack white paste and still dropped 5c :).

Overkill for most people, but I run dual quads because I have a TEC block that adds a ton of heat to my loop. With a triple and dual in series my water temp was still ~6c above ambient just at idle. With the dual quads, my water temp is ambient at idle. Adding more quiet fans is way less...

Depends on not only where the fans are going, but the owners tolerance for noise. My rig used to sit next to a Window AC so noise wasn't an issue, and I was heavily into overclocking and benchmarking so performance came first. I ran 38mm delta fans on fan controllers that I could kick up to...

I just used some old nasty AS Ceramique from the back of my junk drawer since that's all I had left lying around. Dropped about 5c. Unless you go with top tier stuff like Liquid Pro/Ultra, most basic TIMs are within 1-2c anyway. Probably anything will be better then the hard gunk it comes...

I would start by doing what someone recommended and lowering the voltage. Stock voltage on most aftermarket 7970s are ridiculous, at ~1ghz they push volts that most cards can do 1175-1200mhz with. Shouldn't be an issue to drop that 1.256 way down to like 1.13, which will lower temps a bunch :)...

Both your idle voltage and clock speed are contributing to higher then normal idle temps...mostly the high voltage. Most users run 1.6ghz with under voted VCORE at idle, compared to your 2.4ghz and high voltage - your idle volts are what some people run at full load OC'D :). Nothing to worry...

Can't knock the Corsair cases at their price point. Very good value. I'd love the features of a Case Labs or Mountain Mods for $350 but that's not gonna happen!