Build it as raid 5 and partition as follows (all NTFS if running windows 2000 - if NT4 make E drive 2 gb and FAT)
c:\4gb <- windows and program files
d:\30 gb <-database files
e:\4gb <- log files
Install exchange 5.5 into the site with the other server and apply needed patches. Move the database and log files via the management tool as needed.
Configure all the public folders so that they replicate to both servers and let simmer for a few hours depending on your folders.
Then using the exchange manager, while everyone is away, move the mailboxes. Leave the old server running, this way when they come in the next day it will be there to tell outlook where the mailbox can be found.
Once you are sure everything is working, turn off the old computer and let it ride. If everything is still okay – you can remove the old server from the site.
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