To put case back together, align parts carefully (watch the battery cable) then place iPod face down on a mouse pad and push gently from the metal side.

Boy, are these cases hard to open! I got nowhere with the spudger, but I did have success using duct tape. This is worth trying as it reduces the likelihood of scratching the case. Make a tab by sticking duct tape to the metal case starting on the side down by the scrolll wheel and ending up where the metal case ends on the firewire side. Fold excess duct tape back on itself so that it is 2x thick anywhere it isn’t stuck to the iPod. This is where you are going to grab it. Rub the duct tape with a spudger or a fingernail where it touches the iPod to make it stick better. Make a similar tab on the other side. Now grab the iPod in your right hand with your thumb at the 1/8” audio connector, squeeze gently, and pull on one of the duct tape tabs. (I stared with the one of the lock button side, but I don’t think it matters.) It is smooth sailing once the case starts to open up. Clean off any duct tape residue with alcohol wipes before re-assembly.