3G iPods are fairly easy to take apart, and there are many photo guides available online. However, I'm pretty sure the discontinued 4G iPod 40GB was just about the same size as the 3G 40GB, so that wouldn't be an option.
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Cheers! :-)
- JediJoker

Current:
- "ProBook:" 15.4" MacBook Pro Core 2 Duo 2.33 GHz
- Mac Classic II
- Old PowerBook

Moved On:
- "The Book of Power:" 12.1" PowerBook G4 Aluminum 1.33 GHz
- Purple iMac