This's what I was fearing. What headphones were you using?
I also heard some HDD noise picked up in the 'phones, but it's not really audible while music is playing unless it's really quiet music.
I'm going to try an iPod 5.5G 80GB next I think. That's the last version of the iPod that works with Rockbox, the newer Classic versions won't work because of encryption and other things. The 5.5G is also supposed to have higher quality output than the newer Classics; they changed the codec chip from Wolfson to Cirrus Logic -- yes, the same brand as those crappy built-in soundcards on your motherboard. I wonder if the Zune 80 also has a Cirrus Logic chip in it??
Here's the best deal I've found, $215 on eBay: NEW Apple 80 GB iPod Video 1yr Warrenty - (eBay item 230195864892 end time Dec-04-07 23:45:12 PST)
47 of 'em left as I submit this.