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I have a HP from a few years back that has plenty of good hardware to be an HTPC, I just don't want the big ugly case.
How reasonable is it to just gut the thing and place it in a new aesthetically pleasing and smaller form case. Should I worry about heat?
Plus any way to find out the motherboard size so I can pick a new case?
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As long as it's not a proprietary motherboard design it should be no problem. An easy way to tell the probable motherboard form factor is to look at the expansion slots on the back. 1 slot = miniITX, 4 slots = microATX, 7 slots = ATX. Then you'll have to find an appropriate case.
I think heat is only a huge issue on mITX build with real small cases. I think most mATX cases are a pretty decent size, especially for 'regular' hardware. It's different if you're talking about overclocking, big/multiple GPUs and other high power equipment.
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I just did this.I have an old HP with a pentium D Proc. Added a gt40 gpu and threw everything into a
Lian LI pc-v351 micro atx, Was easy had no problems running xbmcubuntu. I am very pleased
My HTPC AMD A8-3870K CPU/ SilverStone ML03B/ASRock MB-A75M /Seasonic SS-400ET/Corsair XMS3 4GB