Thanks! Some interesting suggestions. Hadn't thought of taking a mini apart.
Quo (makers of OS agnostic machines) looks kind of neat.
http://quocomputer.com/shop/prodigyq/
As for the comments about the laws of physics not allowing small and quiet. Well, that's certainly an obvious dismissal, though in this case probably does not stand up to additional scrutiny.
My previous Core2Duo based Macbook Pro (often considered a feat of engineering, packing high performance into a sleek design) used to get super hot and the fans would blow hard often. "That's normal"/ "Deal with it" was the answer I used to get.
That is, until I discovered,
Coolbook. Many will remember this awesome utility which allowed CPU clock and voltage modification.
After undervolting successfully, the
"you can't put that amount of power in a small aluminum frame without noise" argument just went out the window, as I was able to run the machine at whatever load I wanted (used with smcFancontrol), without annoying fan noises (eg 3500+ RPM) or any instability issues whatsoever.
These days the picture is more grim. Coolbook is broken on the newer generation Intel chips (i5/i7), I believe it's because Intel no longer allows voltage manipulation in software, on their mobile chips.
So coming back to the physics argument, the power, thermal output, voltage, frequency, do not all have linear relationships (P=CV²f) and the same can be said for the Mini.
For example, speaking hypothetically, the Mac Mini could have had 5% less performance and virtually no noise, or even the same performance, but with a larger fan, slower RPM, less DB, and the same CFM.
Apple does not care about optimizing for low levels of noise pollution. I'm not saying they have to, because most people don't seem to mind, but it's hard to argue for this this not being the case.
Small and powerful can be done, it's just harder to do, and some small compromises might need to be made...