Sorry for the lack of replies guys, have been moving house all this week.
Look at HFX chassis if you want a completely silent machine.
http://www.mcubed-tech.com/english/index.htm
I had a little look at these, but my main concern is the cost, not to mention the dimensions.
Has anyone considered the eeePCs as alternative?
My main issue with this is the lack of DVI and TV out, as you mentioned. The lack of processing power is also a slight concern.
The MythTV guys have been using MacMini's for slim clients.
I don't think that I'd get on very well with these due to the problems with PXE booting. I also don't believe $700 to be THAT cheap! Furthermore, I'm assuming that with that much power, it won't be fanless either.
According to THG tests (http://tinyurl.com/69aczv) the newest AMD Athlon 64 2000+ is much better then Intel Atom 230:
Now THAT is what I'm talking about! Will definitely look into this further. Gives you the freedom to choose your own motherboard, and therefore graphics, video ports, sound, etc. The only downside that I can see is the larger foot print, but I don't think that will effect the thickness of the design TOO much, which is the main thing. I would definitely be up for giving this a go. What about the PSU though? With the idea of keeping the whole thing fanless, could you use something like this? -
http://www.icp-epia.co.uk/index.php?act=viewProd&productId=15 - Could you get away with a 60 W one perhaps?
The only other option that I can see at the moment, is to use the mini-ITX board that I mentioned previously (
http://www.icp-epia.co.uk/index.php?act=viewProd&productId=186), but in conjunction with a 90 degree riser card and a cheep and cheerful nVidia card. It would keep the thickness and the cost down, and when (or if) the VIA drivers catch up, simply do away with the riser and graphics card. Would this work?