This is a little convoluted so please bear with me as I relay some history:

I have a 2003 G4 MDD single 1.25 running 10.4.11 with 2G RAM. Up till last 
year was very stable. I routinely had it running for months at a time.

Last year I was looking for ways to speed it up. I replaced the video card 
with a Radeon 9600. Some improvement.

About a year ago I started hearing sounds coming from my second internal 
drive, so I cloned it and swapped it for a larger one I had laying around 
for a year or 2.

Early this year I purchased and installed a Sonnet Encore MDX 1.6gz dual 
processor card (along with updating the firmware). It caused the fans to 
start working overtime and being very loud. I had to turn the computer off 
at nights to be able to sleep. Eventually I learned about NAP mode in CHUD 
tools, which took some finding to get the right version, but it seemed to 
work perfectly. However, soon I noticed that the computer would freeze 
occasionally on sleep. Never did that before. I changed the settings so it 
would not go to sleep, but it would still freeze on idle, usually 
overnight. Then, sometimes while using it! Then while rebooting, around the 
end of April, my new secondary drive refused to mount. long story short-it 
had died. I bought a new one, and eventually removed the Sonnet processor 
card and reinstalled the original processor. I turned off NAP mode. The 
computer still freezes! Recently, it has started to also freeze on startup. 
I removed the updated Sonnet firmware and the CHUD tools. I even swapped 
the video card for the old one temporarily, but the freezing continues. I 
moved around the RAM to different slots and tried to start with only one 
stick, but nothing helps. One thing - I have no problem starting in Safe 
Boot mode, even when it cannot start - due to freezing - in normal mode. I 
have not idled the computer in Safe Boot mode overnight yet to see if it 
will be OK.

Any suggestions? Does it sound like software or hardware? Is there a good 
way to diagnose what to do? I'm tempted to throw out the whole thing and 
buy a Mini G4 (I use a bunch of Classic programs, otherwise I'd get a new 
Mini with Lion).

Thanks.

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