Good point about the thermal paste, I'll freshen that up when I get a chance. Temperature Monitor shows the board temperature at 136F with nothing open but the Finder and Temperature Monitor; I'm no expert on this stuff, but that seems a little high to me. When I had it unpacking a large archive with StuffIt this morning, it actually went into suspend due to heat and I had to let it cool off for half an hour before it would finish :/

I'd more look into replacing the fans in your MDD with quieter, more efficient units than pulling the CPU for a single, which will severely hamper OS X performance when you run it. Also look into replacing the thermal grease on the CPU, and graphics card heatsink.

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I'm not really concerned about OSX performance; as I said, this is primarily an OS9 machine. I would be interested in replacing the fans, though - at least the big one, which is a bit rattly anyway. Any idea where I can get a replacement? Also, the heatsink is an aluminum one, and I'm told there was a copper version on some of the faster machines; is there a place I can get one of those?