To answer some of your questions.
Buy a new PC... that thing is 6 years old and therefore ancient. You'll spend so much on upgrades to get it up to snuff that you might as well buy a new one anyway. Besides you are talking about putting a SSD (which is quite expensive) on a pos pc that's so old it doesn't even natively support ssd. From your description, you have a very expensive rig, too expensive to skimp of the most important part.
Don't use a stripped down version of xp, use the full version. There is absolutely no speed benefit, despite some people might say, it only saves you a modest amount of harddrive space. If you want xp to BOOT faster you can disable some of the services... there are tons of sites to guide you through this. Disabling is not the same as removing services. Generally if a piece of software needs a disabled service, it will enable it automatically. On the other hand if you are running a stripped version of xp and something goes wrong, you'll never be sure if the issue is with your emulator/hardware/ect or the fact that you aren't running a full version of xp.
As of this writing there is no benefit to using windows 7 over xp in a cab. In fact there are a few drawbacks (uses more resources, unsigned drivers are hard to install, ect).
Unless your machine is too puny to handle it, upgrading to the latest version of mame is always a good idea when you do a major overhaul. Lots of interesting features and such have been added since 1.35.
I'm not sure what you are talking about, but ipacs are HID devices. They don't have drivers and will work perfectly on any machine. The configuration software written for the ipacs just write their settings directly to the device. Perhaps you are talking about your MAME/emulator configurations? Those can just be copied over. Regardless you are going to have to bit the bullet. If you hdd wasn't working properly on your machine, then the data is probably corrupted. You are going to have to fix a few things most likely.
Thanks for the quick response guys. I really appreciate it.
I decided that I am not going to build a new pc. I just don't have the funds for it right now. The upgrades done to this PC were minimal. The RAM (2GB) was $33.00 and the video card was $40 with a $15 dollar rebate. The SATA card I am buying is $30 with a $15 rebate and the SSD drive (I have 3 of them) have been sitting here since April (slickdeals I couldn't pass up but really had no use for them at the time), so no additional cost to me. For JUST Mame, this pc before the upgrades, is more than adequate for JUST mame, (and other arcade emu's daphne, ect..). In all reality if I can't get a SSD working for the boot drive, then a raptor Drive is less than $30 for a small 36GB (my boot drive now is 10GB), so that should be fine. TO build a modern PC The MOBO alone will cost more than the upgrades so far. The last upgrade I am looking at is a new processor.. MY PC NOW, It has a AMD 3200+ in there (which is lightning fast for mame and 90% of the games mame runs), sure a newer processor with the newer build of mame will probably allow CHD games and such to run better but all that cash for a hand full of games is not worth it when it comes to an entire new PC. I think I can find a better socket 939 processor than what I have for under $50 and double the speed of this PC. The passmark CPU score of the AMD 3200+ is 499 - I can get for $37.99 on ebay a Opteron 180 for $36.00 shipped and the CPU benchmark score is 1217. That is more than double... I am sure this PC will be more than fine for MAME and other emus. I even think I might be able to get some of the newer emus on that configuration to run well. I did add the New HD 6XXX series ATI card as well so I am sure CPU + GPU combo will be great even for a 6 year old PC. But this is a software forum and I will worry about my hardware issues in the hardware forun, though I think a background of my specs was necessary for the thread for proper advice, I really don't want to detract from the software side and go off topic on hardware.
SO THANK YOU.. I will stick with XP. FULL VERSION. Thanks for the explanations.
As for what to enable and disable, anyone kind enough to link me (LMGTFY) to some of the threads about services to disable and such?
I do need networking. My arcade machine is hard to get into and though I meant to do it I never mounted a SD, USB and CD ROM in an easy to get to area inside my coin door - the PC is in the back of the CAB and is hard to get to. It is so much easier to just Network into the drive I need. Also with me using the arcade machine as a jukebox and media playback device (it is hooked up to my 55 inch too) I want to be able to access all the content on my mediatank PC in my office.
I will upgrade to the newest version of MAME too.. Thanks! Even on the old Hardware I think it can handle it.
I am going to want to tweak my Front end and perhaps explore a new Front end as an alternative. Always wanted to try hyper-spin but never had the time or patience to get it working.
Any tricks for it booting right into the front-end other than putting a shortcut to mamewah in my startup?
Any tricks on changing the BOOT Win XP logo to MAME?
Any other advice? All will be greatly appreciated.
Thanks guys!