Ok, let me sum up:
Dead 160 Gig:
Return it and see if you can get a new one.
Put the new one in the Xbox
Use X3 Config Live to "prepare" it.
You don't need your specific dash off the original drive, SO:
Get a copy of Slayers Install Disk or one of the others out there (they have the M$ dash)
FTP through your X3
Upload the M$ dash
Upload a homebrew dash
Upload whatever other hombbrew software you need.
Bottom Line: You need a new HD & the other files you need are available in the "usual places".
(and no, it's basically impossible to unlock a HD from an unchipped box. Not COMPLETELEY impossible, but might as well be. And you don't need to so why kill yourself with that effort?!?)