Background
My old Mac Mini cannot do 1080p and current model has no Blu-ray
Solution: Build my first PC

Design
SFF HTPC that is energy efficient, quiet and cool
Method: stuff oversized heatsink with large fan in Mini ITX case
AXP-140-RT could fit in LM100 Mini (125mm high) but not in Wesena ITX7 (100mm high)

Inspiration
missingremote.com - Intel Core i3-2100T and DH67CF Mini-ITX Motherboard
silentpcreview.com

Components
Case: LUXA2 LM100 Mini case - 4.9"x9.5"x12"
PSU: picoPSU-150-XT + 102W Adapter
Motherboard: Intel DH67CFB3 Mini-ITX
CPU: Intel Core i3-2100T
Heatsink: Thermalright AXP-140 RT - 147x145x70 mm
PWM Fan: Thermalright TR TY-140 - 140x140x26.5 mm
RAM: 4 GB G.Skill Ripjaws X
HDD: Western Digital Caviar Green 2TB WDBAAY0020HNC-NRSN
Optical: LG BT10 Slim SATA Blu-ray Writer
OS: Windows 7 Professional 64bit
Cable: StarTech.com Right Angle Slimline SATA

Images


Notes
Less than 2mm clearance from fan clip to case cover
Heatsink attached using nut and washer instead of backplate for motherboard clearance
Original heatsink orientation clears PCIe slot but extends below optical drive
Current orientation covers PCIe slot but allows fan to blow over entire heatsink
Unused OEM PSU extension cord remains in case

Mods
picoPSU replaced OEM PSU because it was too hot and inefficient
Rewired case display to USB header - http://www.soundgraph.com/forums/showthread.php?t=4557
Rectanglar notch cut in the included Venomous BTK Bolt-thru Mounting kit for fan header
Bent some of the RAM heatsinks slightly to clear heatpipes from cooler
Cut back of optical drive tray for additional clearance
Replaced case cover with 1/8" thick perforated aluminum
Taped off rear vents to optimize cooling

Work in progress
Case cover
iMon software. Remote power and volume working

Test Media
1080p MKV with advanced subtitles on Windows Media Player

Power consumption
Measured with Kill-A-Watt
28 watts playing test media
18-21 watts idle
3.2 watts in sleep mode

Temperatures
Monitored with Intel Desktop Utilities with test media playing for over thirty minutes

Room: 25 C / 77 F
CPU: 38 C
PCH: 58 C
Mem: 33 C
VR: 36 C
HDD: 32 C
Fan 629 rpm

Room: 22 C / 72 F
CPU: 36 C
PCH: 56 C
Mem: 33 C
VR: 34 C
HDD: 31 C
Fan 629 rpm

Associated Equipment
TV: LG 42LE5400
Receiver: Marantz NR1601
Speakers: KEF KHT 3005SE

Stores
amazon.com
heatsinkfactory.com
newegg.com
Onlinemetals.com

References
anandtech.com - Small Form Factor Buyers’ Guide
avsforum.com - Assassin's Simple/Beginner HTPC Buying Guide
hardforum.com
silentpcreview.com - case
tomshardware.com - case
xbitlabs.com - cooler, fan

Final thoughts
PC stays cool and inaudible even at high room temperatures
Very satisfied on how it turned out
Thanks everyone!

Congrats on your build

Excellent temperatures
Is the HDD hard-mounted? Are seeks audible?

Can you provide us with HR pictures?

Excellent build!
Do you use an angled cable on your optical drive?

Originally temperatures were too hot. First setup had the closed cover and Scythe Slim 120mm fan at 1240 rpm. CPU temp was 60 C playing 720p and case was very warm.
The HDD is hard-mounted, I only hear it on Windows startup.

I edited original post to link to large pics, however resolution is limited on my cellphone camera.

Cable angles down from optical drive. I shaved a piece of the rubber boot so fan can sit closer.

Sorry to pull up an older thread. I was wondering if you had issues with the AXP-140 clearing the Ripjaws RAM. Both components diagrams say 40mm, but I know sometimes they are off in real life.

Cheers