Not sure, but would a heated needle or small nail make good starter holes.
Ditto on using a Dremel tool. Some bits can do drilling and at a high enough speed.
I'm gonna check out the sound difference with the cover on and off. Seems RIM designed it to work with that Bose tunnel concept.
But you know what? I don't really care that much about getting good sound out of that little speaker. It seems to work pretty well when I play videos for people, but it's not like I want it to play all that well out of the speaker. I'll use headphones instead.
Interesting concept though.
Sympathies to the member who stripped mined his cover when trying to put holes into it. Any video of the effort.