I thought I'd post an update. If I get any further than this update (I.e. start actual work, instead of just buying stuff) , it'll probably be in a new thread over in Hacks.
I decided on the 5500/6500 logic board. It is small enough to fit in a Mini-ITX case. It has the disadvantages of limited CPU power (unless I can find an L2 G3 upgrade--very rare now days), limited RAM capacity (128MB), only two PCI slots (unless I build an adapter board for the COMM II slot), and no built-in Ethernet. It's advantages are its size, built-in video, and that it is powerful
enough.
Here's the case I plan to use:
http://www.antec.com/Believe_it/product.php?id=MjI0MA==
http://www.newegg.com/Product/Product.aspx?Item=N82E16811129081
It's actually a little cheaper at Amazon, but the pictures are better at Newegg.
There are two other variations of this case with external power supplies rather than internal, and depending on fit, I may need to go to that. But the front bezel on this version looks a little nicer to my eye.
I ended up buying a 6500/300 on Ebay. I think it was about $60 with shipping. I'll add a slot loading DVD drive and some kind of hard drive. The case only supports 2.5" drives. I have my eye on the last of the WD 320GB PATA drives, but that'd be silly in what's meant to be a legacy 7.6.1 machine. Perhaps I'll get the WD 320 GB PATA 2.5" drive and put it in an AppleTV or my G4 Mini and then put the drive from that machine in this one.
To actually do the project, I'll need to:
1) Map out the front edge connector using the 6500's wiring harness.
2) Desolder the logic board edge connector. I'll start by doing this on the 5500/225 board I have on hand. Experiment on the weaker board first.
3) Provide a power supply and switch and LED harness, preferably with a molex connector which will mate with an ATX power supply connector.
4) (Optional) I'll probably connect a cable to the edge connector's IDE bus, so if my PCI card is on the fritz, I have another way of connecting a drive. (There's an external SCSI connector and I don't need any internal SCSI devices so I won't need to wire up for SCSI.)
5) See if it will all fit in the case and possibly do some sheet metal surgery. Boy, I hope there isn't a spoiler in there. At a minimum, I think I'll have to amputate the rear panel and replace it. I just hope there isn't some internal sheet metal component that interferes with some protuberance from the logic board.
6) Install an Acard 6280 or 6880 to provide ATA, and a RealTek 8169 based gigabit ethernet card. Some day, I'd like to build an adapter for the Comm II slot to turn it into a PCI slot. Then I'll move the Acard ATA card there (doesn't need an external connector) and put a Radeon 7000 in the regular PCI slot.
So that's my rather hare brained plan to keep a machine around to run 7.6.1 after I switch from my 9500 clone to an MDD, and to have the legacy machine not take up much space.
The nice thing is that if I later go to an Intel OSX machine, I will still be able to run 9.1 on this compact machine I'm building.