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If I were you the first thing I would look into is some quieter fans. Prior to being in the enclosure you could hear the servers anywhere in the house. That could be bigger and extend the length without causing much bother. I agree, I have looked at a couple different designs for air chambers on the top and bottom but that would add almost an extra 2ft of height. If any of the slag got into your servers, it could short things, clog airways, or act as abrasive on fan motors and other moving surfaces. I'm intending to use the aluminum door idea and keep it closed.
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