The USB stick is made from the standard USB image from genunix.org.
I haven't checked, but I don't think it has a zpool on it, and even if it had 
it would not have been called rpool, otherwise I wouldn't have been able to 
import the rpool from the hard disk.
I did not remove any splash image, I simply deleted the splash image line in 
menu.lst (on the hard disk) to avoid any confusion.
I exported rpool just like I usually umount any UFS before I reboot. I dont' 
think it imposes any problem
I don't think the GRUB hang was caused by a missing menu, but because it hang 
when it tries to find the menu - remember "find /boot/grub/menu.lst" hang? I 
think that's why GRUB hang.
I just removed USB stick and the extra disk, so I only have one disk left. When 
I boot from it,  it hangs at GRUB prompt again. So basically this sympton 
doesn't have any thing to do with the USB stick or the extra disk.
Is there a debug version of GRUB that can be installed that can produce more 
verbose output?

Following are known:
- The rpool is fine (it could boot with some effort)
- The O/S is fine (same reason)
- GRUB is partially good (it can find rpool and boot from HD with some effort)
- GRUB hangs trying to find menu.lst file

Thx,

Sean
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