Note: Some of the instructions are very similar (if not the same) as the other iPods so don't be surprised if I repeat myself...
We all have or know of someone who has an iPod with a dead hard drive. Of course you can simply buy another drive but you're back to the same power-hungry, failure-prone, fragile rotating media. Instead, upgrade your iPod to use Flash Memory. Sure a hard drive can hold all 30,000 of your songs, but even a 4GB card can hold over 24 hours of music - I usually change out songs often enough that I don't need to carry 20+ Gig of songs at all times.
You can also check out my new Bluetooth 5G iPod Video at iPodHackers.net
Step 1: What You Need
Although you can get adapters for the 4G iPod cheap on eBay, Tarkan Akdam is in my opinion the only person in the world selling a reliable adapter for the 5th Gen iPod Video. Get yours HERE. Don't come crying to me if you use some cheap Taiwanese adapter and burn up your iPod!
2) iPod-Opening tools (non-marking plastic tools and/or flathead screwdriver). Tarkan will ship you a set of these with your purchase.
3) You will also need some hot melt glue or double sided foam tape.
4) Of course, you will need a fully ATA-Compliant Compact Flash card. Any size will work, but you can now get 8GB cards for under $60 as of this writing. I've had good luck with Transcend and Sandisk. Check the specs, not all cards will work.
5) Oh yeah, make sure you start off with a fully functioning iPod! Don't assume that the broken unit you bought from eBay simply has a bad drive.
Step 2: Open Your iPod
I do have to warn you that if you have not opened a 5G unit before, don't just pull it apart after you crack the case open. The battery is connected via a ribbon cable on the lower right corner (ipod face down). Use a small screwdriver or some other tool to pull up on the connector to free up the cable. I made my own tool to do this as I feel it places less stress on the connector.
Step 3: Prep the Flash Card and Adapter
The adapter is designed to fit perfectly into the iPod's frame so there is no need for any additional glue or tape to hold it in place but it is up to you.
Step 4: Remove Hard Drive & Install CF Card
Remove the two rubber bumpers, toss them.
Carefully fold back the drive as shown. Next, remove the drive by flipping up the locking tab on the drive's ZIF connector and separating the drive from the cable.
Drop in the adapter/card assembly into the iPod and insert the ribbon cable into the adapter's ZIF connector. Once the ribbon cable is fully seated, use even force across the whole locking bar to snap it into place. Don't just push on the middle or you might break it!
Step 5: Test The iPod's Functionality and Restore
Plug your iPod into the PC using the dock connector. If iTunes does not automatically open up, do so now.
At this time, iTunes should recognize your iPod and will give you the option to restore the iPod to its original settings. The sequence of events will be roughly as shown in the pics.
Once the restore process is complete, your iPod will display a message telling you that the unit has been restored and should appear on your iTunes device list.
Load a couple of songs and test it.
If all is OK, snap the iPod closed and enjoy!
Step 6: Before And After
iPod now weighs approx 20% less!
iPod is now much more rugged and will no longer suffer from shock-induced hard drive failure.
Now go and make yourself a Custom iPod Boombox and visit www.iPodHackers.net!
Thanks to Tarkan Akdamfor his support and advice in the making of this Instructable.
Check out my other instructables for more iPod hacks.