It was a toss up where to put this, either here or in storage. I chose this forum as the topic is specific to the Zen.
The new Zen from Shuttle leaves just enough room to suspend a hard drive without using the 5.25" bay. All that need be done is leave out the removable drive case that fastens below the floppy bay. Without any added cooling in an ambient temperature of 21-22C the drive running idle is stable at 41C. An hour and 45 minutes of running two simultaneous processes of CPUburn on a P4 3.0 Ghz with the CPU @ 1.325 volts netted a 1C increase in idle drive temp (though this CPU turned out to be unstable at this voltage). The top of the case was very warm to the touch while CPUburn was running so I imagine the internal case temp was pretty high. I don't yet have any software to test loaded drive temps so idle temp is going to have to do for now.
Update: Copper wire is not needed!
Click images for a larger pic.
Across the top is a green mini bungee strap. It, like all the other parts, came from Home Depot. The bungee straps come in a pack of 8 and multiple color options for your viewing pleasure. They are 10" in length. I used 2 of them to suspend the drive. The pack of 8 costs about $2.00.
Below the strap is a 25 foot roll of nice soft 18 guage copper wire. I used about 6" of it.
The roll costs about $3.00. -not needed
To the left of the roll is a #10 x 5/8" sheet metal screw. It came in a bag of 10. I used 4 of them. The bag costs about $1.00
Beneath the roll and slightly to the right are 2 of the white 1/4" ID plastic clamps. They came in a box of 18. I used eight of them. The box costs about $1.00.
Below the screw is a quarter for scale. Total cost for parts was about $7.00. If you have this stuff lying around, it costs nothing. -total updated cost is about $4.00
I chose to cut the hooks from the bungee straps with a pair of wire cutters. This left the already clamped cord ends in place, making the cords the perfect length for suspending a drive in the Zen. The clamped bends that the cords come with work as a natural knott to prevent the cords from passing through the clamps.
The metal wire of the hooks is thin and simple to cut if you have a good pair of wire cutters. You end up with a pile of loops like pictured above.
A nice feature of using this suspension method is the ability to tilt the clamps providing an excellent means of fine tuning both the level and depth of the drive after it's installed. Just loosen the screw, twist as needed, and retighten the screw. This is especially helpful given what little clearance there is for the drive.
There is no need to drill or cut any part of the case for this installation. The #10 sheet metal screws fit securely into existing holes in the case. You'll need a good pair of wire cutters, a flat head screwdriver, and a phillips head screwdriver.
Suspending hard drives seems to be pretty old hat around here but as the Zen is pretty new I'll be glad to answer questions anyone might have.