Quote:
Does it matter if this bigger drive becomes the primary or secondary drive?

No.

Quote:
what is the best (and/or easiest) configuration?

Putting *only* the 120 gig drive in place (leaving the 18 gig drives completely out of the equation), running Mark's bigdisk builder on it, and putting Mark's 2.0 bigdisk player software in place.

Carefully follow the instructions in the drive upgrade guide, following the parts that talk about "complete replacement of the primary disk drive".

After you're done, make sure that you can successfully synch a few tunes to the player before you turn it over to its new owner.
_________________________
Tony Fabris