Is this an interesting problem? It only happens occasionally, say 1 out of 100 times.
Over the years, I've always had a "permanent" SD card in all my XO systems (many dozens of SD cards in all). The SD cards have one ext2-formatted data partition, plus a swap partition.
I can NEVER recall any incident where I could attribute "failure to boot" to the SD card. [Note that if an XO fails to boot, I normally don't get to see the /var/log/messages from that boot attempt.] My experience with "failures to boot (after getting past OFW)" is that they occur 10 out of 10 times (not 1 out of 100).
I've had a handful of incidents where the SD card became "dead" - (electrically unresponsive) - but the XO would still boot - it would just not "see" the SD card.
In general, an XO with a corrupted SD card would boot - but accesses to one or more directories would time out (and 'ls -l' would show question marks). Nowadays I always 'synch' after explicitly writing onto an SD card, and run 'fsck' whenever I have an SD card removed from its XO.
My suggestion would be to try "repairing" (fsck?) the SD card. Though you may not have the time to try this, you might check if the same SD card on a different XO-1 still has this problem, and if a different SD card in the original XO-1 still has this problem.
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