I'll share my thoughts on some of the rigs posted.
@shibob I did look at just using L channel initially as its costs are a lot lower. I think it works in some cases but found that isn't as easy to make adjustments so it works really well for on type of GPU, but the rear rail is fixed and wouldn't accommodate longer/shorter cards as easily. This particular issue is one of the main troubles with the main stream extruded case that you find on ebay/amazon. The rear rail will hit the GPU or the riser cards so the position needs to be adjustable in my opinion. Looks like you have quite a few of the same rigs so for your setup I have no doubt that the L channel material is less expensive.
One thing in particular that I am doing is adding plastic feet. You can buy this for the extrusion but I've designed my own part for this. If you frequently need to move a rig, or place it on a nice table, the metal frames will eat your table tops! The plastic feet really make a difference. No reason why you couldn't do this on the L channel either. This is just one of the little details I've added after playing with the case (and ending up with scratches on my work tables).

I did see the server style cases as well and have a friend looking at those as they have around the same cost as the cases I'm designing. You hit on the main issue which is cooling. The dense layout of the cables really limits airflow and you end up with a lot of trapped heat. If you try to exhaust this, you need to have higher CFM fans that push the air through and overall it seems like the enclosure is fighting purpose.
For my design I wanted to make sure I could move the heat away from the cards w/o it being a power hog. Before the chassis I was running big 20" fans to move air across the rigs, but from a power perspective that is quite expensive and on top of that it wasn't that effective. With the four 120mm fans I have now on the rig, the cards are running much cooler now and it also moves the heat away from the chassis. The GPUs act as channel to guide the air through from the rear to the front of the case. It also picks up any of the rising heat off the motherboard but thats fairly minimal.