about the coolness factor, but are they safe?  Also, acrylic is so
brittle!  Gah...

And it scratches so easily.

My question:  what is the cheapest way to *quietly* make a system cool?

Since you mentioned cheap, then water-cooling is out. After that you are stuck with 
some form of air cooling. If you want it quite, then go with big fans. Also mount your 
hard drives and or cddrives on rubber isolators. 

Couple of weeks ago I build a Athlon XP 3000 in an Antec Sonata Case 
(http://www.antec-inc.com/pro_details_enclosure.php?ProdID=15138). Instead of having 4 
or 5 80mm fans this case has 2 120mm Fans and then 1 80m min the power supply. The 
hard drives also mount on rubber grommets so the vibration of the hard drive is not 
transmitted into the case. 

I replaced the stock 120mm fan (that was much quieter than 2 80mm fans) with 2 Antec 
SmartFans. These fans have thermisters in them (a type of temperature dependent 
resistor) that causes the fan to move more air as the case gets warmer (so when it is 
not working really hard it is very, very quiet). The system was so quiet that the only 
way you could tell it was on, when it was under the desk, was to see if the light was 
on. Not only was it quiet but it was very efficient. 

Once you quite the case down, then you can start to focus the CPU heatsink. There are 
a number of good quality heatsinks that are fairly quiet. The Thermalright SLK-900u is 
supposed to be very efficient and very quiet, but a bit expensive. It uses a larger 
fan (92mm) to help reduce the noise and a good heatsink design to make it 
efficeint.(http://www.thermalright.com/slk900.html). Zalman also makes a number of 
very quiet heatsinks but they require a bit more tinkering to get them to work right. 
(http://www.zalmanusa.com/)

I good place to start looking at quieting a PC would be Silent PC Review 
(http://www.silentpcreview.com/). The do decent reviews of quiet pc related products. 

I'd love to [eventually] get a nice watercooler, in fact I've been
thinking that one nice watercooling system might be adapted to cool a
handful of systems or even a small cluster?  Is this safe?  I suppose
for multiple systems, a failover would be appropriate.

The biggest problem with water cooling is failure. If you loose the pump, your system 
is toast. If you have a leak, your system is toast.

And on this note, does anyone know exactly how harmful *not* using a case at all
might be?  

The case is there to protect the computer from you, to provide some EMI shielding, and 
to provide proper cooling. You need air moving across your system to keep the 
components cool. 

If the metal box is indeed as important as I think (for
protecting both ourselves and our computers) then said water-cooled
minicluster might be housed inside an old washing machine or something.
Maybe I should just plan on building it inside a used, working fridge?
= )  Can I put the storage array in the freezer?  Sheesh, maybe the
whole thing should be built in a box-freezer...

One word: Condensation. Wet electronics are bad. That is also the biggest problem with 
using peltier devices. They tend to cool the processor so much that you end up with 
condensation.


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