to4st3r :
BambiBoom, thanks again for your help. We ended up getting 15 Dell T5400s (dual processor quad core) and processing to $-wise they were a great investment. Total of 8 cores for $200 each. I owe you several rounds of beer! (PM me your address

I am back here with a follow up situation. The amount of heat and electricity consumption is pretty high (as was expected). We are all running headless + Umbuntu server (terminal).
Any suggestions to reduce energy consumption + heat dissipation?
My main strategy so far is get rid of the Nvidia 200w Quadro cards with cheap Dell FH868 $5 video cards. The bios doesn't allow me to run without the cards. They are on all the time, so power saving features w/ sleep doesn't apply.
What do you think?
p.s. This winter we'll be making a RaspPi cluster to see how effective they are with our metrics: 1) $ to core ratio 2) energy consumption 3) heat dissipation
to4st3r,
I very much appreciate your reporting back on what sound like a very interesting project. Your thanks can be expressed in a PM about your work, which I will keep confidential if you so request.
Performance: For the lead system consider a PERC H310 RAID controller which will convert the disk system to 6GB/s for about $50-60 . In the T5500, I added one and without changes to the Samsung 840 or WD RE4, the Passmark disk rating changes form 1940 to 2694. Also, consider PCIe drives.as you may be able to use M.2 AHCI. I added a Samsung SM951 M.2 AHCI to an HP z420 (E5-1660 v2) and the already fast Intel 730 480GB Passmark disk score of 4794 became 11559.
Heat : Yes, the Dell Precision T5400 is beautifully made and ultra-reliable, but a bit hotter running, partly due to the DDR2 RAM which in my T5400 regularly ran up to 80C. The T5500 uses DDR3 which runs some what cooler- low 60's. Running the cluster without a GPU is a very good idea. My T5400 uses a Quadro FX4800 If the individual system do need to run storage HD's that would reduce heat and power consumption. For continuous running, consider adding a pair of small diameter- 90mm or so- extractions fans to the high end of the back panel connected to a spare 4-pin Molex to draw hot air through the chassis and out the back.
Power: I can't think of another way to reduce power consumption except to shorten the processing time as much as possible- which takes more power,... I'm not sure of the nature of the parallelization of the cluster is better when more or less identical, but for the lead system, consider adding a
Tesla C2075 6GB GPU coprocessor. which will add 448CUDA cores processing power And 515 Gflops double precision to the effort. the C2075 also has a single DVI monitor output, the only Tesla with that feature, so it can run the monitor without another GPU. The last time I was at my local particle accelerator I saw a C2075 on the beach in the server room. Unfortunately 225W so more heat and power, but might advance the processing of the initial data stream in a way that will will multiplied by the parallelization, increasing performance. If the processing time is shortened that might also to a degree reduce the power consumption and heat.
At the accelerator facility, they were playing with a Raspberry PI cluster- 10 of them running an MIT program which with a display that converted various physical parameters into colored shapes. I have photos of it and I wish I'd asked more questions. It was not a practical application, but demonstrated a considerable computational density. For the experimental simulations, they use eleven parallel dual 14-core Xeon systems each having 4X Tesla K20X and I think that may be tied to Oak Ridge as well, so if, they're impressed with a Pi cluster,... A friend is running a quite complex aerospace control system off a pair of them.
Well done!
Cheers,
BambiBoom
P.S.>
Current Project:
HP z620 (Original) Xeon E5-1620 4-core @ 3.6 /3.8GHz) / 8GB (1X 8GB DDR3-1333) / AMD Firepro V5900 (2GB) / Seagate Barracuda 750GB + Samsung 500GB + WD 500GB
[ Passmark System Rating= 2408 / CPU= 8361 / 2D= 846 / 3D = 1613 / Mem =1584 / Disk = 574 ] 7.13.16
Now:
HP z620 (Rev 2) 2X Xeon E5-2690 (8-core @ 2.9 /3.8GHz) / 40GB (4X 8GB +4X 2GB DDR3-1600) / Quadro K2200 (4GB) / Seagate Barracuda 750GB + Samsung 500GB + WD 500GB / 800W > Windows 7 Professional 64-bit >
[ Passmark System Rating= 2589 / CPU= 20703 / 2D= 728 / 3D = 3542 / Mem =2397 / Disk = 587 ] 8.2.16
System: $270
CPUs: $320 ($160 each)
CPU Riser: $150
RAM: $165 (32GB DDR3-1600 ECC)
GPU: From Precision T5500
Disk: HP Z Turbo Drive M.2 256GB: $150 Not yet installed. The Passmark score for this drive is 12602 so that should improve the 587 score of the 2010 Seagate 750GB!