I decided to do some cutting on my 6500 and thought I'd post what I've done. After getting the TV/FM Tuner card a while back, my Mac's average temperature went from 78 degrees Fahrenheit to 86 degrees because of all the heat that little tuner puts out. This average temp is with the 400mhz Sonnet G3 1MB cache upgrade. While this temperature is still quite cool, (and far cooler than my PCs temp), I wanted to add a little ventilation to my cramped 6500.
I thought an Apple logo on the side of my case would look nice, so here's what I came up with:
I used a dremel to cut out the Apple logo and a drill press to drill holes in the metal casing. The drill press was warped so it was impossible to drill the holes accurately and they look pretty bad up close. I plan to put some kind of metal mesh in behind the plastic cover as soon as I find what I'm looking for. The drilled holes are just to get me by until I find the right mesh.
I had planned to attach a case fan to the screw post on the inside of the case where the cutout is, but I don't think it needs it. If you put your hand near that cutout, you can feel the air moving plenty.
I cut out the same logo in both sides of the Mac, but I didn't bother to drill holes in the other side since the warped drill press does such a bad job. I'll just wait until I get the mesh and then make a cutout in the metal case instead of drilling all those holes. I also cut out a top bezel to fit a CD/DVD drive.
If you'd like to see more pics of the before, during, and after, you can look at some that I've uploaded here:
My Mac Pictures.
BTW, that's a Yamaha 4416S CD burner in the bottom bay and a Pioneer DVD-ROM U05S in the top bay. I have a Yamaha 2100S on its way and will be customizing it to fit the bottom bay when it gets here.