didn't read through all of the posts. But your Hard Drive is overheating. The bearing are beginning to die. I have an old hard drive that can't run for 10 minutes before clicking and dying. Then once it cools off it works for 10 more minutes. My iPod also did this, if the hard drive was on fore more than 10 minutes it would click and die. Put some heatsinks on it and see if it lasts longer. If it does then you know it is heat related. Another way to test... when it dies, put your hand on it. If you can't put your hand on it for more than 30 seconds then it is overheating.
BTW, Apple replaced my pod... no questions asked... on the spot at the apple store.
[ October 13, 2003: Message edited by: jeffberg: Mac Capitalist ]