Ipod gen 5.5, made capless output mod, don't have the max output swing

[Spiralman]

The normal build should work fine.  The changes discussed here just raise the volume by a little less than 2dB and are fairly pointless.

You mean i do the hardware modification part:
1. Remove dc-blocking caps from line and hp outs
2. Short LOUT2 and ROUT2 and make it a "new" HP_COM
3. AVDD2 to AGDN1 through coupling cap (~47uF)

All this while firmware leave as it is (stable or latest dev build) and it will work fine? 

[saratoga]

Let me clarify the above, I mean the changes in this thread are unnecessary.  If your modifications require other software changes, you'll still need to make them.  I can't comment on that, I'm not familiar with whatever you are modifying. 

[no_one]

Performing this mod changes the output ground reference so the software mods in this thread need to be performed in order for the iPod to be usable (as a listening device).
I've forked the rockbox repo and I added the modifications, you can compile it directly as it is or directly download compiled firmware available in the "compiled binaries" folder. There's both voltage versions for the DAC chip, 2.5V and 3.0V.
https://github.com/bob808/rockbox

[no_one]

Also I just realized you need to make sure the headphone jack metal part does not touch the metal part of the case. Usually headphone jacks have the large metal that contacts the case at headphone ground, and the case is referenced to the internal ground.
So just pull it a bit, or isolate it in that area. Else you would get crackles and such.