I've been doing investigating into the Core2 mod. I've come away with a few thoughts and conclusions that it doesn't make sense for this current build.
Throttling and Low-end Performance
I've been testing the throttling ability of the X6800 CPU with another motherboard (Asrock 775i65G R2.0). The limitation of the X6800 is the fact it only goes down to a 6x multiplier. Unfortunately Intel limited the low end multiplier despite being "unlocked".
With cache disabled and at 266 MHz (host frequency), I get 3DBench scores ranging from 20.4 (11x multiplier) down to 16.1 (6x multiplier). This is a ~21% range of performance. With my current Pentium 4 651 processor, I get 3DBench scores of 33.3 (17x) down to 27.7 (12x). This is a ~17% range of performance.
What this means is despite having an unlocked multiplier, the X6800 isn't really that much better when it comes to scaling performance at the low end based on multplier alone.
What really seems to make a difference for low-end performance is changing CPU host frequency. If I throttle the Asrock board to 95MHz with cache disabled I get 3DBench scores of 7.1 (11x) down to 5.6 (6x).
What I really need to do is figure out how to throttle the FSB on this DFI G7S620-N motherboard. Unfortunately the stock BIOS doesn't provide any option for that. I tried Rayer's SMB tool, but it doesn't support the PLL chip used on this DFI motherboard.
I found a reference in this thread to a tool called SetPLL, but I can't find any downloads for it. The forum it seems to have been originally posted on just has some dead Mediafire links.
Performance at the High End
My current GPU (GeForce4 4200 Ti) limits performance at the high end. Pairing a Core2 processor with a GPU from 2002 likely won't have any real benefit on performance with this GPU. If I were to do a Core2 mod, I would likely need a faster GPU to really take advantage of it.
For example, this Radeon HD 3850 AGP card:
The attachment Saphhire Radeon HD 3850.jpg is no longer available
I've considered doing a build using this Radeon graphics card paired with a PCI GPU like an FX5500 or Voodoo3 3000. I think a Core2 processor would pair better in a set up like that.
In a future build, I might strive for a 10-OS system (adding Vista and Win7 to the mix) with the above dual GPU combo. This would be an entirely new build though.
Motherboard Swap?
Another thing I am considering is replacing the motherboard entirely. I still want to squeeze in an AWE64 sound card to have greater DOS sound compatibility. I've looked at other possible motherboards with an extra PCI slot. Switching boards would enable me to keep the current setup I have, plus add an AWE64.
If I end up swapping the motherboard for this build, doing a Core2 mod with the DFI G7S620-N motherboard becomes moot.