I've decided to build a second computer for chat, browsing, and occasionally movie watching.
Here's the list for the initial build:
Case: Habey EMC-600S
MB: ASRock E350M1
Ram: OCZ Platinum OCZ3P20002GK 2X1GB @ 7-7-7-21-1T 1333MHz 1.5V (left from upgrades)
SSD: Patriot Warp V.2 32 GB(left from upgrades)
SATA cable: OKGEAR OK3437 RT
Fans: SUNON KDE1205PFV2(intake, 50X50X10mm) and 2XSilenX IXP-11-14(exhaust & CPU, 40X40X10mm)
CPU heat-sink: SilenX IXN-40C
OS: Ubuntu 10.04 64 bit
Monitor, keyboard & mouse shared with the main computer thru KVM switch.
Initial mods: move the power plug from the side of the case to the back-plate and fill up the resulting case hole with grey epoxy, replace the annoying blue power LED with a white one and focus the LED on the power sign, replace the blue LED on the DC-DC converter with a green one, replace the original CPU heat-sink with the SilenX(the heat-sink needed some trim at the base to remove interference with the MB capacitors), replace the original MB power cable with a custom made one.
Result: Noisy & hot; to get around 55C processor & 45C internal case temperature(25C room temperature) on idle, all the fans has to run around 3500 RPM - time to evaluate the modding possibilities.
The most obvious mod is to place a 80-120mm slim fan on the top of the unit, and remove all the small fans. This mod means that the SSD has to move, and the holding bracket has to go. The only solution to move the SSD is is to exchange the DC-DC converter with a PicoPSU, and use the room to place the SSD. Options: use an 1.8" SSD mounted vertically, or take out the PCB from the Patriot SSD, isolate it, and place it under the motherboard. Since my only 1.8" SSD option(OCZ Onyx 32 GB, the only one under $100 AFAIK) is no longer available, time to take out the Patriot SSD PCB from his case, isolate with 0.8mm thick self-adhesive closed cell foam, and place it under the MB. Check the clearance between the top of the RAM(highest edge in the case) and top of the case: 13mm - time to add a slim SlipStream(120X120X12mm) to blow some air into the case.
Fan filter: Silverstone FF121(left from upgrades)
Case fan: Scythe SY1212SL12M(left from upgrades)
Power supply: PICOPSU-80
Leftovers: SUNON KDE1205PFV2, 2XSilenX IXP-11-14, Habey DC-DC converter(inefficient BTW: 1W off(74mA@12.2V) and 2W on(146mA@12.2V))
Result: with the SlipStream fan running around 900RPM, both case & CPU idle temp is around 38C(25C room temp).
Power consumption on idle is 14.1W(12.2V*1.16A), and barely move up on normal use.
Pic 1&2: Initial build; observe how crowded is, not much room left for airflow.
Pic 3: Patriot Warp in pieces.
Pic 4: Motherboard & SSD in place; notice the space between the edge of the data connector and cable; if I don't do something about, the cable will slide out from the connector.
Pic 5&6: Modded cover, fan, filter and assembled top cover.
Pic 7&8: Close-up of the SSD data connector; a piece of foam keep the connector in place.
Pic 9: The original place for the power connector; the purpose of the other hole is unknown(reset?).
Pic 10&11: Close-up of the CPU heat-sink with the trimmed wings.
Pic 12: Clearance between the top of the RAM and top of the case = 13mm(15mm(measured)-2mm(thickness of the top cover)).
Pic 13: Back panel from inside.
Pic 14: Ready to close.
Pic 15: Back panel from outside.
Pic 16&17: Power consumption.
Pic 18: Screenshot during the power consumption measurement.
Pic 19: Discreet white LED.
Pic 20: Finished unit in his place.