Hi again,
Ok, some progress here and more debug info...

I've made a few modifications to the makeimage.sh script which got me
past two things:
1. loop devices were being used in /dev/loop/# where they always
failed, they are now being used in /dev/loop#
2. the symlink to /dev/loop failed because it always complained that
/dev/loop and /dev/loop/0 were the same, this would in turn cause the
grub command to fail.  It is now symlinking to /dev/loopy

here is my makeimage.sh diff:

------------------------8<------------------------
40,43c40,43
< if [ -d /dev/loop ]
< then
< LOOPD=/dev/loop/
< else
---
> #if [ -d /dev/loop ]
> #then
> #LOOPD=/dev/loop/
> #else
45c45
< fi
---
> #fi
100c100
< ln -sf "$LOOPD"0 /dev/loop
---
> ln -sf "$LOOPD"0 /dev/loopy
119c119
< grub> device (hd0) /dev/loop
---
> grub> device (hd0) /dev/loopy
------------------------8<------------------------


...and here is the entire output of my latest attempt.  It fails with
an error 22 upon reading the newly created partition, which then
causes the grub install to fail later.

Thanks again for anyone taking time to look at this,
--Michael I.

------------------------8<------------------------
[EMAIL PROTECTED]:/usr/src/astlinux-devel# ./makeimage.sh.new 128

This script will create a bootable AstLinux image from the
development environment in this directory. Every care has been
taken to prevent damage to your host operating system, house, etc.
HOWEVER, IT IS ALWAYS POSSIBLE FOR SOMETHING TO GO WRONG. I CAN
NOT GUARANTEE THAT THIS SCRIPT WILL NOT DESTROY YOUR MACHINE OR
ANY DATA ON IT

Press enter to continue, or CTRL+C to exit

You will need to write down the number of cylinders, heads, and
sectors for fdisk.  Bad things happen if you mess this up!

========================================================================
                                bximage
                  Disk Image Creation Tool for Bochs
        $Id: bximage.c,v 1.31 2005/11/20 20:26:35 vruppert Exp $
========================================================================

I will create a 'flat' hard disk image with
  cyl=260
  heads=16
  sectors per track=63
  total sectors=262080
  total size=127.97 megabytes

Writing: [] Done.

I wrote 134184960 bytes to disk.img.

The following line should appear in your bochsrc:
  ata0-master: type=disk, path="disk.img", mode=flat, cylinders=260,
heads=16, spt=63

You need to run fdisk manually to partition the image.
Please write down or memorize the following instructions:

press 'x' - extra functionality
press 'h' fill in heads - probably 16
press 's' fill in sectors - probably 63
press 'c' fill in cylinders - this changes
press 'r' return to main menu
press 'n' to add new partition
press 'p' to choose primary partition
press '1' to set partition number
press Enter keys to choose default value of First Cylinder parameter.
press Enter keys to choose default value of Last Cylinder parameter.
press 'w' to write partition table and exit

Press enter when you are ready

Device contains neither a valid DOS partition table, nor Sun, SGI or
OSF disklabel
Building a new DOS disklabel. Changes will remain in memory only,
until you decide to write them. After that, of course, the previous
content won't be recoverable.

Warning: invalid flag 0x0000 of partition table 4 will be corrected by w(rite)

Command (m for help): x

Expert command (m for help): h
Number of heads (1-256, default 255): 16

Expert command (m for help): s
Number of sectors (1-63, default 63): 63
Warning: setting sector offset for DOS compatiblity

Expert command (m for help): c
Number of cylinders (1-1048576, default 16): 260

Expert command (m for help): r

Command (m for help): n
Command action
   e   extended
   p   primary partition (1-4)
p
Partition number (1-4): 1
First cylinder (1-260, default 1):
Using default value 1
Last cylinder or +size or +sizeM or +sizeK (1-260, default 260):
Using default value 260

Command (m for help): w
The partition table has been altered!

Calling ioctl() to re-read partition table.

WARNING: Re-reading the partition table failed with error 22: Invalid argument.
The kernel still uses the old table.
The new table will be used at the next reboot.
Syncing disks.

GRUB Help:
grub> device (hd0) /dev/loopy
grub> root (hd0,0)
grub> setup (hd0)
grub> quit

Press enter when you have this memorized

Do it...

    GNU GRUB  version 0.97  (640K lower / 3072K upper memory)

       [ Minimal BASH-like line editing is supported.   For
         the   first   word,  TAB  lists  possible  command
         completions.  Anywhere else TAB lists the possible
         completions of a device/filename. ]

grub> device (hd0) /dev/loopy

grub> root (hd0,0)
 Filesystem type is ext2fs, partition type 0x83

grub> setup (hd0)
 Checking if "/boot/grub/stage1" exists... yes
 Checking if "/boot/grub/stage2" exists... yes
 Checking if "/boot/grub/e2fs_stage1_5" exists... yes
 Running "embed /boot/grub/e2fs_stage1_5 (hd0)"...  16 sectors are embedded.
succeeded
 Running "install /boot/grub/stage1 (hd0) (hd0)1+16 p (hd0,0)/boot/grub/stage2
/boot/grub/menu.lst"... failed

Error 22: No such partition

grub> quit

Probing devices to guess BIOS drives. This may take a long time.
Done.
[EMAIL PROTECTED]:/usr/src/astlinux-devel#
------------------------8<------------------------
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