I have one of these controllers and it only takes it about 30 minutes to do a rebuild, but it's running on an AMD x2 5000+, 2 gb ram and windows xp 32.
As for hard drives, all I can say is this, I have about 70 hard drives laying around, more if you count dead ones. It seems that all the manufactures all have bad lines from time to time. One of them going back into the past a bit, bringing up 2 WD drives, the dreaded 4.3 gb Caviar and the 20gb Protege, not to mention the countless Seagate cheetah's that failed me. I worked at a computer shop and we got a run of bad 40 gb Seagate Barricuda's. The only drives that have seemed to hold up where the ones that were maxtor made when they were maxtor. I have 10 80 gb maxtors, 4 of which ran 24 / 7 in my old server for about 5 years, and only now, 8 years after all that are they starting to go bad. I have not encountered alot of dead maxtors, but I have seen and experienced it. Also noting, some of the drives that maxtor sold that failed were made by Quantum. The worst drives though I have seen where the old Conner drives. But really coming from experience, I quit the fan-boy thing becuase I have been let down at one time or another with each company, and I find it fruitless to do ones of those "OMG don't buy brand X, it was horrible, I'll just go with brand Z in the future" Just do your homework and almost any hardware will last you a while, and if you take care of it, that makes a huge bit of difference too. Alot of people forgot giving their hard drives enough cooling and thus shorten their life as well, look at how DELL and HP build machines sometimes, the internal temps are within the limits of the hardware, but running near the limit doesn't always prove good. Just like what would happen if you drove your car constantly just under the red line, it would most defenitely have problems faster.
Wow I went off topic, but anyways, my controller is running 4 x 200 gb drives now, I am thinking about getting some 500's cause they are cheap, or maybe 750's. I could let you know what happens once I make the decision. To me that controller still has life in it unless you want raid 5 in a ultra new box. Alot of normal folks have nas / file server's about because it was an old pc. You have to see what the old pc runs to make something useful. Otherwise if you really want a file server invest $$$$$ in SCSI / SAS and an awesome controller, might as well buy a real server too. lol You should see the point I am making no ? I came across this article looking to see what people have accomplished with this controller.
Anyways, that's my 2 cents worth.