Best way around it is not to use too big a drive. Dig up an old 3GB or thereabouts, and the tolerances are much less exact that on a 40GB or other new drive.
One day, a web server at work (running FreeBSD) started to throw a bunch of disk errors. So we backed up the files, brought it down, and popped out the hard drive. When we opened the hard drive case up to see what sort of craziness was going on, there was a pile of metal dust inside from where the head had crashed the top platter and dug a groove. The drive worked long enough for us to get the data off though, we didn't lose anything. That was maybe a 3GB drive. They're relatively rugged.
My pal mashie modded a couple of 40GB drives for one of his projects, and broke them both.