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I don't think it's illegal, but it's probably prohibited by your service agreement. Also, it might not be very doable. I think newer SIM cards have more protection against cloning. Anyways, you can even find articles about it on eHow.
 
Nah, I am sure it will have no effect at all on the warrantee, and to be safe, I'll put the original in the Model S and the cloned one in my phone!! Gonna upgrade it in November anyway... ;)

Google on the subject worked as well, but will wait to hear how you brave souls pulled it off first... :D

I thought I read somewhere it said "built in SIM". NOw not sure if by "built in" they meant "standard" or "available" or if they meant actually "permanently built in"
 
Don't even try it. If TM has made the enclosure custom, they probably added an IDS to the case. Best just leave it alone. (If you want to look around, use an inspection camera or borescope. Just don't open anything.)