I know this thread kind of died a few days ago but I just received some information that I wanted to post on the forums regarding the controller heat output issue that may helpful to the OP or at least someone else who comes across this thread on a Google search.

Anyway, the other day I picked up a Dell PERC 6/i which runs an LSI 1078 chip. Without any air flow at all, it does get hot enough that if you hold your finger to it for a few seconds you have to take it off or risk a burn. However I have just rested a very low RPM 120mm fan next to it and it's completely cool to the touch now. So it seems while they do heat up, the actual heat output is quite low, low enough that the heatsink is colder than my skin at any rate ATM.

Incidentally I picked up the PERC 6/i (used, but verified functional) for only $175USD from a non-eBay store - LSI 1078 chip (same as on their highest end internal stuff), 2x wide SAS ports (8x SATA/SAS total without extenders), 256MB DDR2-667 cache (not upgradable). IMO a pretty good alternative, considering its just a re-branded high-end LSI... half the price of anything comparable (likely helps that it's used, but you won't find a used current-gen Areca/3Ware/etc so I feel comfortable with the statement).

We'll see if I end up doing a review of the thing or not. I likely will at some point, but I'll only have 3-4x WD 6400AAKS/LS + ACARD 9010 available to bench with so I won't be able to do anything too fancy. If anyone happens to want one before I get around to doing this, send me a PM and I'll send you a copy of the procedure I used to flash it from Dell -> latest LSI firmware if you've never done it before. Still trying to figure out how to get LSI drivers to find it (Dell drivers work and are relatively new, but LSI has a slightly newer set out that I want to try).