Woo-hoo! Success!
Got the 160GB Agility 2 installed this afternoon in the optical bay. Wasn't planning on doing this for about 2 weeks, but the SSD optical caddy arrived, my Sunday afternoon freed up, and I figured out I had all the tools I would need. I plan to reinstall Mac OS 10.6 and my apps from scratch on the SSD, use it as my boot drive, and put my data and such on the iMac 2TB internal drive or FW800 externals.
I didn't time it, but from disconnecting my iMac to hooking it back up, I'd guess it took about 1.5 hours. I've taken apart iMacs, iBooks, MacBooks, and MacBook Pros before, but never an Aluminum iMac.
I printed out the OP's instructions, as well as the
iFixIt iMac Intel 27" Optical Drive Replacement guide. Here are things I learned that I haven't read elsewhere:
Any suction cup will work to remove the glass. And you do not need 2 but only one. I took a cheap plastic suction cup off the kitchen window where my wife had a pretty thing hanging. I imagine a dollar store or walmart would carry these for cheap. Part of the reason I decided to do this project this afternoon was that I was testing the suction cup and stuck it to the iMac and the corner of the glass cover popped right off.
Even though I was in a brightly lit room, it was dark under the LCD to see to remove the cables. Being my first time in an AL iMac, I wore a headlamp to help me see the cable connections better.
I have had a hum on my iMac since day one due to the hard drive resonating. To fix this, I have had a padded mailer under the base to reduce the hum. While putting in the SSD, I noticed the two screws at the top of the HDD were not completely tight. I tightened the screws, and there is a large decrease in the hum. It is slightly present, but not nearly as loud as it used to be. I've even removed the padded mailer and now just have the iMac sitting directly on the wooden desk.
The SSD caddy I bought on ebay linked above was from seller novapcs. The title of the auction is "2nd HDD caddy Apple OptiBay SuperDrive Replacement SATA." (this is for future readers when the auction link expires) I paid $16.99 shipped from New York; it got here in about 6 days. UPDATE: Now the seller has jacked the price to $99.99, so unless he comes back down in price, shop around and you can still find the exact same caddy for under $20. It does not have brackets for the iMac, but you simply remove the SuperDrive and you can reuse the existing iMac plastic mounting bracket to secure the caddy with your SSD to the iMac. I DID have to drill 4 holes in the plastic sides of the caddy to attach the iMac SuperDrive bracket. I did this by fitting the caddy in the bracket and then just holding it in place and drilling through the four side screw holes (gently and very shallow, although you can go a cm or so without hitting anything, so there really isn't any danger to your SSD).
Hope this helps. Good luck to others putting in the SSD. I can't wait to get the OS installed later this week.