there are a few options i can pursue. nano itx boards (since mini is out of the question), or transplant a full HD media player into the case. size of circuit board, height of key concern. mac mini's back is more ideal for a single layer of ports (if I want to install any motherboard or circuit board inside) since the "top"part of the back is used to vent out hot air http://www.granneman.com/images/macMini2006.jpg or maybe I should use for non-computers purpose? like a raid box for 2.5" hdds? ideas please..
If you're not shy of Linux, try getting something like the BeagleBoard XM - 1GHz ARM CPU with HD decoder. Really tiny piece of kit and would be ideal as an XBMC media centre platform. As it's ARM, you're not getting Windows on there though. Although there are many versions of Linux that are already pre-compiled for ARM.
So many possibilities! Faux AppleTV/ media streamer would be cool, if you can indeed get a HD media player in there successfully. Would make one sexy router-firewall. Can't remember the manufacturer off the top of my head, but they make tiny boards with embedded BSD variants on. Or an eeePC type thing, low power web browsing PC that can stay always on? Hope you get many more ideas, this could be an awesome little project