Shuttle K45 - $110 from eBay (sold all parts inside for $80)
Intel D510MO - $70
4GB OCZ DDR2 800 - $50 (used)
2x 2TB Samsung F3 Ecogreen - $110 each
120watt PicoPSU - $75 (used)
WHS PP3 - $75 (used)
92mm Nexus Silent
All for around $500. Should I have gotten an HP MediaSmart Server instead at the same cost? Probably...but it wouldn't have been as fun to build.
Have had the box up and running for about 2 months now, as a backup/file server and serving .mkv files across 2 WDTV Live players.
The board only has 2 SATA ports, but I only need 4Tb and when I need more, I will probably just spring for 2x 4Tb drives and upgrade to Vail. I tried Vail Beta and it was slow on the system. If I could get Vail installed on a small SSD and still use the 4Tb in a pool, that would be my path later on.
Not a single issue so far. Drives are quiet. Running fan at 50% RPM through BIOS. NO heat problems.
As you can see, lots of room in the K45. I can easily get 2 more HDs in there. 1 under the drive cage, and 1 vertically above the CPU side. All the space was created by removing the stock PSU.
Have to change the design on the faceplate.