This is a wrap up for this thread. From my perspective, the project is complete and time to move on to the next project. Feel free to comment. Please PM me if I don't respond to questions within a reasonable time.
Bill of Material:
Motherboard - Intel DH61AG : Source - Amazon
CPU- Intel i3-2125 (selected for the HD3000 support) : Source - MicroCenter
CPU cooler - GELID CC-SSILENCE-IPLUS : Source - Newegg
Memory - Patriot 8GB SO DIMM 1333MHz, 2x4GB : Source - Newegg
HDDs - Hitachi 250GB HDD, 2x : Source - Frys Electronics
Misc. - Dual 2.5" mobile rack : Source - Frys Electronics
Mini-PCIE WiFi card - Broadcom BCM94322MC : Source - Amazon
SATA Cables - 6 inch Rt. cables : Source - estore.circuitassembly.com
Antenna Cables - 6 inch U-Fl to RSMA cables : Source - Mouser Electronics
Small WiFi antennas, 2x - Source - unknown - prior projects
SATA power cable to mobile rack - custom from two lab stock cables
Power On switch, reset switch and LEDs - front panel kit - Source - MicroCenter
Top Panel USB connectors : Source - Mouser Electronics
Top Panel USB cables - modified from Lab Stock
ABS plastic sheet (black plastic parts) : Source - Tap Plastics
System Fan - 92mm PWM fan : Source a scrap Shuttle PC
Apple Power Mac G4 Cube (used) : Source - Craigslist
JB Weld : Source - Orchard Supply Hardware
ABS Cement : Source - Orchard Supply Hardware
Primer, Grey - Rust-Oleum : Orchard Supply Hardware
SATIN stone grey, Ultra Cover - Rust-Oleum : Orchard Supply Hardware
#6-32 Phillips Flat Head screws, 4x : Source Orchard Supply Hardware
Modified brass standoff, 4x, Lab stock.
Power Brick, 19.5VDC ---4.62A, Max Power Output 90W : Source - Dell p/n CM889 input 100-240VAC
See the thread above for OS X installation tips for this motherboard. I am running Lion 10.7.3 and most all is working, including sleep and wake from sleep.
New in this set of photos is the riser bracket for the mobile rack to get it above the 92mm system fan output path. Also, I am using a modified top vent grill (this mod may be responsible for the 3 to 4 degree improvement is idle and full load temps that I see). Idle is 28 to 32C; full loaded at 1 hour is 66 to 68C; both at a room temp at 70F.
Using a Kill-a-Watt power meter I saw 30 to 35 watts idle and 70 to 75 was under full load (this is a AC line monitor if you are not familiar with it).
I left off the proximity switch primarily because there is no space for in the original position. The addition of the power switch, LEDs, reset switch and 2 x USB port in the top vent slot may not suite the purest. However this added switch panel makes the system much more useable (for the way I use a system anyway).
I would like to high light the SATA cables. The source (see above) ships same day or next day by US First Class Mail and has a full selection of cables in wide selection of lengths.
And antenna cables have always been a pain to source. However Mouser had them in stock at a reasonable price.
Have fun with the hacks,
neil