Okay, more progress. Yesterday I ordered 4 of these:
here
They are Zalman Fan Mate 2s - basically a little pot that you fit inline with a fan and it allows you to gradually drop the voltage to reduce its speed. They can be had from about £3 each.
The idea here is to reduce fan speed enough that the fans become inaudible at full blast as dictated by the onboard controller, but hopefully not so much that they can't do their job. I think its a given that the fans at reduced speed wouldn't stop it redlining if we were asking it to drive a PA at full welly, but at home the headroom indicators suggest that even at considerable volume the amp is barely getting into a jog, so at a lower speed (and thank you Tenson for prompting this line of thought with your comment about quiet fans achieving it by spinning at reduced speed) they might just be fast enough and remain quiet. I checked it with the guys at MC2 and they thought it might be worth investigating and gave me some useful information re operating temperatures.
They arrived today and as I was working at home this afternoon, I had a chance to play with these things.
I fitted one to each fan and mounted them on an old permostat box. The leads are long enough to be able to route through the case and out of a conveniently placed hole where there was a blanking plate for fitting a remote option. I shall name it the "Stealth Box"
I set the amp so that it gives me a red light at the first headroom reduction point rather than shutdown as my probe thermometer isn't suitable for running with the lid down and I needed some way of knowing when it was getting a bit too warm without actually going as far as shutdown. I have a suitable twin sensor thermometer coming tomorrow which will help fine tune it - a Revoltec Thermoeye, again a PC cooling type product, about £12. Twin sensors will be useful as it means I can monitor each channel separately, battery driven and good up to 120c.
I ran the amp for a while with the fans disconnected so that it was up to the sort of temperature that would have the fans running full speed, plugged the fans in and dropped the lid, I set the fan speeds to minimum and adjusted up until with my ear next the intake hole I could just hear them, inner fans first then outers, and then adjusted them down until they were inaudible.
I then put Bob Marley and the Wailer's Exodus on at a volume just past what I would normally consider my max volume and waited for the red light (no neighbours today). It did eventually, but took a while. Slight tweak of the fans and off again ... a result, silent fans, and the ability to take some welly and still stay cool enough for my purposes.
Auntie can't hear the fans ... and if she can't hear them they can't be heard, and its not redlining even at volumes I would barely consider ordinarily, let alone the low volumes where it was a problem before. I'm pleased. Long term, one of these might be better run off an independent 12v supply: