This is a hack by the most basic of definitions. Seriously, the tool list is only two items long and the second item is “butterknife”! No real technical problems here; you just need to format your new 80gb harddrive as vfat and then mirror the RCA files from the original 40gb drive. It’s nice to see someone else try this before you go knifing around.
On the topic of MP3 players: have there been any other network attached players besides the Rio Karma?