Thanks again wonko, appreciate the input. I hope I don't go through that many stages! Unsure what to do about the expansion slot, as dimensioning and machining the case for it looks likely to be difficult. Have an initial spec, and first sketches of a case.
Intel D945GCLF2 (dual core atom, gigabit ethernet, shocking graphics, pci expansion slot. 2 sata ports, ide header that I hope to use as two more.)
pico psu, I think anything 90W or over will do fine. A bit worried about hard drives drawing a lot of current on start up, otherwise it looks reasonable.
four 750gb samsung drives, software raid. ubuntu server based.
There isn't a case available that suits this, which is an adequate excuse to play with metalwork during exam term. This will probably be steel as that's easier to source than aluminium. This will make it heavy, which should help with vibrations and so forth.
I'm never that confident with images, but presumably these will work for at least a while. The resolution is rather higher than Id hoped, but they're 90kb a piece so could be worse.
First draft
Second
First one allows some form of vibration isolation for the hard drives. Is taller and larger than the second. Easier to work with once assembled.
Second is about the smallest I can see this being. Square thing at one end is a 120mm fan. Any thoughts on whether one 120 or two 92 is the better idea? Intention is intake fans, and air leaves through holes in the back. Might put a fan on the back, having difficulties sketching the rear panel. All dimensionally accurate wrt the dimensions I've found so far, even the very ugly hard drives. I would love to know the height on the mini itx board, or the dimensions for the rear panel but intel have not told me this.
Assembly idea is 6 sheets of 2mm metal, four 8mm bars in the corners. Mechanically fixed. If steel, might weld the bars to the base plate. I'm not welding aluminium. I'm also aware that I'm meant to be making copper blocks at present, that's been placed on hold while I try to work out how long i'll keep the motherboard for.
Component price looks to be around 160 all in. 90 for board, 60 for psu, 10 on misc. Reasonable. So a few questions I guess
The current intention is to directly screw four hard drives into a rigid, heavy chassis. The only attempt at vibration reduction being
http://www.overclockers.co.uk/showproduct.php?prodid=CM-005-AF What're the odds that this is a terrible idea? Vibrations will be transferred to chassis, and I don't really want this to make noise. I can't suspend the drives with the second draft, and sourcing grommets for hard drives appears impossible. Might make some. Is this worth the effort, or will directly screwing the drives into the chassis be alright?
One 120mm fan, or two 80/92mm? Fan speed not an issue, linux does a pretty solid job of that, as do inline resistors. Not going passive after a thread in the hard drives section, will blow air over at least one surface of each drive. I'm wondering how much effort I'm prepared to put into keeping this quiet, getting down to suspended hard drives and a single 7v 120mm would be nice but difficult.
Similarly, fans at front or back of case? Back is traditional, probably quieter, but might remove the option to use 120mm fans.
In-Win BM648 Mini-ITX Case is 6.8 litres, the second draft 6.3. Not exactly a massive space saving then. Cheers