>  9atom boots fine so I think I owe Erik another beer :)
> 
>  Just for completeness, the system is an oldish amd - nforce2
> motherboard, SIL3112 SATA with a couple of 300g ST3300831AS disks.

take a look on segate's site for a firmware update for those drives.
i'm not saying that's your problem, but older AS drives (consumer)
have had firmware problems.

i'll just beat a dead horse here and repeat that it is very important
to choose a high-quality disk drive, and fewer platters leads to better
reliability.  (fewer heads to crash.)  here are the spec sheet numbers
i think are important
unrecoverable read errors       < 1 in 1e15
mtbf                    > 750000 hrs    (1% afr)
duty cycle              100%
unload cycles           > 200000

mostly enterprise drives fit this definition.

- erik

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