Thanks to all that worked on this site and the PhatHacking tool. In a little under an hour I was able to swap my HD out, hack my Phatbox, and get the new drive working on my Phatbox. Awesome! $60 for an 80GB HD instead of $350 from the now defunct Phatnoise.
The only remaining issue I have is PMM thinks my drive hasn't been initialized even though it works.
Also, I would consider adding an option to the Hack tool to create new disc/ load drivers/ prepare for hack all in one step.