I make these all the time. I love Foundation as a framework for WordPress and Joomla templates, but I find it to be a bit bloated for email.
One thing I will strongly recommend though is a service like Email on Acid. This allows you to preview your email in 70+ clients and configurations including web, desktop clients and mobile clients as well as tools to see how "spammy" your email appears, code helpers, etc. 100% worth the money!
edit:changed the number of clients/configs.
Client support seems to be pretty limited: http://www.emailonacid.com/blog/details/C13/a_how_to_guide_to_embedding_html5_video_in_email
Gmail won't let you create any html codes for embedded video, and also won't show you any videos that someone else sends. You might be able to do it with mailchimp (I think you could, since you can edit html using it), but if you look at the browser support table in the link above, many people would not get the results anyway.
Unfortunately, it looks like the best possibility is either the raw gif, or for large links, an image inserted, that links to the external URL. Too bad, I would love to see support for this!
I went through this same headache a few months ago, trying to design a new template for my job. (Side note: You might want to think about mobile compatibility. At least for our users over half of the emails sent are opened in mobile now)
This company, Email on Acid and their little side project Emailology seriously saved my mind. Email on Acid you have to pay for, but it will give you inbox previews that are very accurate. It'll also help you optimize your code.
I used the Boilerplate from Emailology and it was a fantastic starting point. For your own sanity though, you are probably going to want to build it in tables, I'm sorry to say :(
You can try this.
Do you have an example of how it is breaking? Emails are a pain to format, you have to pretend you are writing html in 1995. Use tables for formatting, css has to be inline, padding and margin don't work on certain clients, each email client is worse than the last.
Yes, just looked into it myself the other day. Here is some links, to how you do it.
How to embed HTML 5 video in emails: http://www.emailonacid.com/blog/details/C13/a_how_to_guide_to_embedding_html5_video_in_email
Link to auto-generator. http://v4e.thewikies.com/
Here's a good one that EmailOnAcid gave away.
And actually, while looking for the above one, I found this recent post on their blog: 600+ free templates
For future reference, and if you haven’t already, you should get an account with Email on Acid so you can efficiently QA your HTML emails.
When I sent out HTML emails at a previous job, I found the best solution was to always use nested tables. No <div> or <span> tags. This fix is a pain in the butt for lengthy emails but I was able to avoid those strange breaks you’re experiencing.
Also, if your client is using Outlook to view the email, ask that he/she check their preferences and un-select Word as its email viewer or editor. That pesky preference – Yahoo! Mail, too – ruins the best emails.