k_graham
I'm wondering if anyone has either built a server with integrated controllers and LAN or knows of manufacturers using these?
Yes
Look at Intel offerings, but check the specs anyway to be sure.
You will probably need to run SME 8.x to get support for the newer motherboards.
Re controllers (and by that I assume you mean hardware RAID array's), you are usually better off to use software RAID1 with two drives and a standby spare, unless you are going for a larger RAID array.
In the "older days" of hardware RAID, it was always a good idea to buy an identical spare disk controller card in case of board failure, that way your disks were still usable simply by swapping in the new controller card.
These days perhaps you need or should buy a spare identical motherboard if you insist to use onboard controllers with hardware RAID arrays.
If using non server (but good quality) grade motherboards, I usually buy a spare identical system that can easily be swapped into situ in the event of a m/b failure. It can be used as a workstation or backup server until needed in an emergency. Simply swap the drives and be up & running quite quickly. Hardware is relatively cheap these days,
Many professional users of SME suggest to buy a low end server grade product from Dell or HP etc, to get better reliability, support & warranty etc. Ask the sellers re Linux compatibility, but most manufacturers have models that support Centos 4.x & 5.x.
Also just a thought but if the drives can be hot swapped I was wondering about the feasibility of having perhaps a set of mirrored drives with possible Hot spare and assuming a free 4th slot having that as the backup drive instead of USB?
AFAIK the currently used kernels in SME 7.x & 8.x do not support hot swapping of drives, so that functionality may be sometime in the future.