Is the replacement machine the same as his old one? Hard drive transplant from one to the other?
Probably not going to do the warranty on the new machine any good, though.
Without gaining physical access to the innards of the new machine I think a copy from one to the other is probably the best you can do.
Could he remove the hard drive from the old machine and substitute for a suitable paperweight before returning it in case a better solution comes to mind?
As TB says, hard drive format is likely to be linux and the content on it could well be proprietary format and encrypted but you never know...
<resists the temptation to take apart his DVD recorder - but for how long?>
Kevin