Note that one thing I did recently was move the USB connector back so it doesn't hang out a bit. This allows front-front tiling. In this layout you could have a 200x200mm tiling with the USB connectors in the middle and power coming in on opposite outside edges. The catch is that you cannot plug in a USB cable unless one of them is flipped around back-front. So you could do eg. 200x300mm 6 boards, or 200x400 8 boards, with all facing inward except one flipped to get access to the USB (or a vertical facing USB conn. exists out there).
Another thought I had was a K32 10x20cm board, perhaps instead of K64. The difference is that the main power supply area would come right down the middle of both and there would only be one PIC for the whole K32, with each bank being 16 chips. One power connector at the back for the whole K32. Unlike the K64 with this layout we actually gain more parts savings since we remove a power connector and PIC and a few other bits. It's still probably not that significant overall since ASICs are the main cost.
I would like to know if you (BKKCoins) think overclocking the klondike board would produce gains high enough to justify doing it. If I could get another 15% with a good liquid system over air then I'll think about doing it. I could rig up a custom system on the cheap, but in the end I kind of doubt that it would be worth it.
I really don't know. But maybe later some testing can give some clues as to how much cooling will translate into speed increases.