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Huzzaa! Great points, Jeff. My solution to this for max reliability is:
1GB CF for / (to house /boot, /sbin, /bin, /root, /etc -NOTE putting etc
on this is getting harder with everything being part of the distribution
and it all goes in /etc now).
2 drive raid that houses /var, swap and /tmp. This requires that I move
database files for postgresql and mysql and /var/www on RH/Fedora
systems. /var is RAID0 and the other 2 are RAID1 for speed.
Most of my systems these days are LAMP boxes. So database and apache
gets pounded on. I much prefer separate RAID5 schemes (3 hot plus 1
spare) for database files (I had been getting small 15k rpm 9GB SCSI LVD
drives and putting them on their own controller until recently - PCI-X
controller cards are F A S T) and similar for the apache files.
/home is typically where the apache files get located in a hosted setup
so it is the mount point for the apache raid.

Recently, I've been using almost all SATA drives. The cost of the
multiple controllers is low enough that I have been able to stuff the
box with 3-5 (and whole MESS of fans for the 10+ drives I use...).

To realize Jeff's process requires skipping SATA and going SCSI. 9 GB
SCSI are still produced in large quantities. They are BUTT fast and BUTT
reliable. With proper case design and the correct scsi controller
card(s), hot swap is possible to minimize service interruption.

I have not seen hot-swap SATA yet. SATA still can't support the
sustained throughput of SCSI. SATA _still_ doesn't get hot enough to fry
eggs on like SCSI (thankfully :) since it only recently added 10k rpm
and has another 1-3 years to get 15k. By then, SCSI will be up to 25-30k
and 1280 MB/s sustained transfer rate. And also using separate power
supplies fro the drive components is likely (I'm thinking phase-change
cooling at this point).

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