Most of my friends know I have a fairly kickass file server. It started back in early 2005, when Krogebry and I worked together to build a file server for the geekpad. Once we moved to the geekpad 2, it kept growing, and once I took over the server in '07, its seen 10 hard drives and a total of 5.7TB of storage.
Specs:
AMD 3500 w/ ASUS A8N-SLI motherboard
1GB (2x512) DDR 3200
10x HDDs (3x1TB, 4x500GB, 3x250GB)
4U Server Chasis
Antec 650W power supply
It was a pretty beefy box in its day. Heck, for a file server its still a pretty decent system. However, the underlying architecture had some issues:
* A8N motherboard has issues supporting all 8 drives in its SATA ports. max 2TB per 4 ports
* PCI Express was being shared with a hungry 6800GTX Ultra Video card
* No RAID
In the beginning, we went for cheap. Really cheap. We figured we did not want to strip the server in RAID1 (because if one drive died we loose it all) nor did we want to mirror the drives (too much wasted space), and lastly we didn't want to buy all 10 drives at once.
Whats new with this FS01?
RAID5: I decided that it was worth it to invest in a RAID controller and put all the drives in some type of hardware raid setup. The 3ware 9650SE-8LPML card was a great candidate for this. Cost? $470
Server Architecture: While the old AMD was great, it was desktop grade, and it'd be nice to get some server quality stuff in there. But what really tipped the boat was when I got a call from my friend at (redacted =P ) ... he had a development/engineering version of an
Intel s3420gplx motherboard AND a
Xeon x3470!! Cost? ZERO!
New Power supply: The old Antec power supply is great. Really, it probably would have been fine to keep. But I decided that since that PS has been running for 4.5 years, it'd be a good idea to get something new. Its an
Antec TP-750. Cost? $104.99
The issues with 'new stuff'When my friend mentioned he had a Xeon + MB he had laying around, I thought it was a one or two year old engineering board they had no use for. I never dreamed that it was a BRAND NEW, just released board! And not only is this board new, the whole platform is new! It uses DDR3 1066/1333 ECC ram and has a LGA1156 socket. That caused a few issues:
RAM: No one in western washington has DDR3 ECC RAM. I called and called, with no luck. I took a 'hail mary' pass, and decided to call up 3D Corporation, based in Bellingham. They no longer do retail sales, but figured it was worth a try. And guess what! 3GB (3x1GB) ECC 1066 DDR3 ram! I wish they had 1333, but I'll take what I can get. besides the difference isn't that bad. When I move to ECC Registered 16 or 32GB ram, then I'll go 1333. Cost? $120
Cooling: So as I'm driving up to Bellingham, I notice something...
the proc has no cooler! SHIT! well, perhaps the LGA1156 is like the new Core i7? Nope. Fail. 3D had nothing. There is only one other computer shop in Bellingham that might have a cooler. Nope, they didn't either *(funny story though.. they DID have an LGA1156 ASUS board.. wonder why they had a board and no cooler for it? duurr)*
So... go home and I'm thinking .. crap, I have everything but cooling. and this thing NEEDS cooling. So I figured, what the hell.. another Hail Mary pass: lets call Best buy.
Now at this point, all of you techno-geeks are going to say HAHAHA YAH RIGHT. Best buy has decent computer parts? PLEASE! Well guess what.. they did! Its a
Corsair H50, bundled up hybrid water cooling with a radiator fan thingy. WAY overkill, but w/e. it fits so lets get that! Cost: $79
Why Hitachi? In part: because they are the only 7200RPM HDDs out there at 2TB, and they don't have any dreaded reports of bad firmware.
But its a DEATHSTAR! no. Please pull your head out of your 2001 ass. Hitachi is arguably the biggest hard drive manufacturer out there. Most apple laptops ship Hitachi. They are reliable and in my case, cheap. I scored a great deal through Dell.com, making them only $144 and free shipping. You can't beat that for 8 drives! I was looking at the WD EADS 2TB drives, but they cost way too much.
Parts List:


Total Cost: $1465 ($2496 for all components)
Dismantle the old systemThere are two things that will be sticking around for the new build: Case and 1TB HDD (OS drive). Since we can hold 10 drives (no CDROM), I figured we'd go for 8 drives+OS drive+CD/BDROM.
What a mess. The SATA and Power cables were everywhere. but it stayed cool.


Once everything was ripped out, did some cleaning and got the new board ready for installation. Damn, I knew this radiator thing was big, but oh I hope it'll fit somewhere!

Completed setup, hooked all the drives up, and the radiator fits surprisingly nicely between the cdrom and the power supply. The bottom is wedged in by cables, the top is held down by a bracket on the case, and its held towards the wall by the thick water cables going to the processor. I may screw it down at some point, but its actually pretty solid in its current position. Also thought about cutting a side exhaust for the radiator, but after a few days of testing, this thing is cool to the touch and the CPU runs just under 35C.

All done! Now comes the daunting task of copying data from the old drives. Since we had no case, I figured the drives would work nicely on the top of the case:

I could only get 6 drives on there at a time. There are 6 SATA ports on the motherboard, plus two from the PCI card taken from the old system. When you subtract the OS drive and CDrom, you get 6 extra spots.
I placed foam on the top of the chassis to keep the vibrations down, and then static bags on top to keep the foam to shock the drives. This all works great, but we're missing a big problem... cooling. After first boot, and let it run for 20 mins, the drives on top were between 40-45C. I don't like the drives over 35C.
So yes, I rednecked it (4wheeler, use what works, right?) by putting a window fan on the front of the case:

Of course, that didn't really help all that much. Lots of airflow, but none of it directed. I needed to create a wind tunnel:

With the cardboard on top, it makes the air flow through the drives, then push out through the sides of the cardboard or go down through the case. Did some benchmarks, and the drives now run a cool 28C.
Of course this was all done because its temporary. The transfer will take a day or two, so I didn't want to put undue stress on drives that have been running 24/7 for 2 to 4 years.
Coming up... Part II -- setting up the RAID, software configuration, etc.