http://www.apple.com/jp/support/datasheet/ipod/index.html
ここの情報を纏めてみると、

機種 H(mm) W(mm) D(mm) 体積(cm^3) 重量(g) 密度(g/cm^3)
1st(5/10GB) 102 61.8 19.9 125.44 185 1.47
2nd(5GB) 101.6 61.4 19.9 124.14 185 1.49
2nd(10GB) 101.6 61.4 18.4 114.78 185 1.61
2nd(20GB) 101.6 61.4 21.4 133.50 204 1.53
3rd(10/15GB) 103.5 61.8 15.7 100.42 158 1.57
3rd(30GB) 103.5 61.8 18.7 119.61 176 1.47
4th(15/20GB) 104.1 60.9 15.7 99.53 158 1.59
4th(40GB) 104.1 60.9 18.5 117.28 176 1.50
Photo(20GB) 103.5 61.8 16.1 102.98 166 1.61
Photo(60GB) 103.5 61.8 19.1 122.17 183 1.50
5th(30GB) 103.5 61.8 11 70.36 136 1.93
5th(60/80GB) 103.5 61.8 14 89.55 157 1.75
6th classic(80GB) 103.5 61.8 10.5 67.16 140 2.08
6th classic(160GB) 103.5 61.8 13.5 86.35 162 1.88
touch(8/16GB) 110 61.8 8 54.38 120 2.21
mini(5GB) 91.4 50.8 12.7 58.97 103 1.75
nano 1st(1/2/4GB) 90 40 6.9 24.84 42 1.69
nano 2nd(2/4/8GB) 90 40 6.5 23.4 40 1.71
nano 3rd(4/8GB) 69.8 52.3 6.5 23.73 49.2 2.07
shuffle 1st(.5/1GB) 85 25 8.5 18.06 22 1.22
shuffle 2nd(1GB) 27.3 41.2 10.5 11.81 15.5 1.31

touchは容積比でminiより既に小さく、

classic(80GB)は最も厚い2nd(20GB)の半分以下の厚さ。

薄いのは6.5mmでほぼ限界だらうか。これがベストフィット?