In the process of building a 120GB Rockbox iPod Video 5.5G. No tools needed, thus, no scratches. (Lucky to be born with tough fingernails -- it can be done!) Might go the 240GB route some day but it would be awfully expensive and still require (I think) a special Rockbox build to get above the 137GB barrier. iTunes is reporting 111.3GB so I suspect the hardware part is OK. Now all I have to do is install Rockbox and sync the .ogg files.
Congratulations to the Rockbox dev team on release 3.2! Long live Rockbox!