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This ice theory is probably the better way to attempt this. Cut out the block like you mentioned in your first post, don't install it, fill the cavity with water, throw it in the freezer, take it out when it is frozen and install it on the CPU. No worries about leaking or filling.
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When doing this method w/ a phase change system, the problem is that the ice will not freeze flat. It will most likely be convexed. MAYBE it will be flat/smooth enough, but if it isn't, and it's not making good contact, and the CPU get's over freezing, then you have some melting/leaking going on.
As for using it in non phase change cooling, and still using the O-ring... I think that is a good idea
. Just have to account for how much volume you are going to loose when the water contracts, then decide how you want to make sure there is still good contact between the water and CPU/die after the loss. Which wouldn't be too hard. I will try it out... sometime
