ok i have an idea if you were to figure out a way to get power to the zune then you could do this. As far as syncing why cant you just do a wireless sync then you will never have to take it out. If you were able to make sure that you dont hit it with you elbow then you should be ok. you could also try to make a custom fiber glass enclosure around it with a hole in the bottom for a charger to be plugged in and hard wire it to the car. as far as the sanding goes you will have to sand the whole thing or it would look weird with part smooth and part textured.
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