Hi PiR,
Wow, sounds like you got some problems there. First up, get CGX v4 if you can. Version 3 has lots of bugs. Also, there is a chance I got lazy and my code won't work with it anyway. Let me know if it complains/fails.
I have an 040/25 + BVision and a couple of cooling fans in the case - but not on the 040 (just a very big heat sink) - because the case design means a fan can't fit there.
Luckily, I managed to get the heatsink in thermal contact with the tower side panel which is 2mm thick aluminium and performs as an excellent passive cooler!
The 040 is even more power hungry than ther 060, but I don't get power problems. However do I feed power into the motherboard at two points, so that may help you too.
First up, I have all the required voltage rails (+12VDC, +5VDC, 0VDC, -12VDC) connected through the standard A1200 power connector.
The old A1200 PSU lead is connected to the tower PSU and fed though a hole in the back of the tower.
This one is essential as it's the only convienient place to feed the -12VDC rail you need for audio / serial.
Next up, I supply additional +5VDC and +12VDC (and the 0VDC rail) through the motherboard floppy connector. Lemme just take a look at it...
Aha...if you imagine the A1200 mobo in front of you such that the PCMCIA is on the left (like in the normal A1200 case), the +5VDC rail connects to the left hand pin of the floppy port. The two centre pins are 0VDC and the right hand one is +12VDC. These are fed from a standard IDE power cable from the PSU.
I mounted a power amplifer heatsink onto the Permedia2 (perfect fit!) and have a spare case cooling fan blowing air across the mobo/gfx card.
My machine is stable as a rock 99% of the time, except when I get tired whilst programming :-)
Hope this helps,
K