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This is how i disassembled my 1st generation iPod and did a custom paint job, it is also the first time I used an airbrush. Having worked on the Apple Newton since the MP130 came out, I thought I would tackle the iPod (love small eletronic devices) to give it a different look. I just don't like plain white.
Lets start by taking the iPod apart. I used a Guitar pic (thay always seem to be laying around everywhere!) and inserted it in the side and kind of gave it a wiggle and worked my way around the outside till the back poped off. 
After you get the cover off disconnet the battery cable gently and remove the battery 
Next remove the hard drive by grabbing the copper connector and gently wiggle and pull the connector till it comes loose. 
Get a #6 torx (got mine from Sears) and remove the 4 torx, two are hidden underneath foam pads by the HD connector. Then remove the mainboard. It should come out by lifting from the bottom. 
What you have left is the front shell of the iPod. I taped up the front and back to keep paint overspray from getting on the display. 
I then took a file to the edges to give it a semi-rounded 3rd generation look. After filing, I used an 800 grit sandpaper on the edges followed by a 1000 grit paper over the whole iPod so that it would help the paint adhere better. 
Next step is to give it several light coats of paint. I used Createx acrylic paint made to spray in airbrushes right out of the bottle (Iused black as an opposite to Apples blah white) and heat set it with a hair dryer between coats. the picture shows the first coat. Remember to go light with the paint otherwise you get runs. 
I got some stencil material from Walmart (I found out that frisket film is better to use as its got an adhesive back and is easier to cut) and drew my design, then I used and xacto knife (also at Walmart) to cut it out and tape it to the iPod.  The flame template was a disaster but the skull worked good so I decided to draw the flames by hand directly on the iPod. I did do some practice first though:) 
I thought a diamond plate would look good on the back so I did a template for it and sprayed it with a light gray. It came out so-so but I still like it. Next time I'll make the diamond plate smaller and it should look good! 
I lifted out the scroll wheel with a peice of duct tape and sprayed it black then took my skull template and sprayed it a bright white (Createx paints seemed to work great) after everthing was dry I sprayed a clearcoat to protect it all.  Here is my finished mod! I couldn't get a good pic because of the flash, but it looks great! Can't wait till my next PodMod ! 
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