Ya know, I am just thinking out loud here but... You mentioned formatting the drive after taking it out of the firewire case... if that was the last format done to it, I wonder if that is the issue - that because it wasn't formatted by going through the FW/ATA bridge in the case, maybe there is something missing on the drive that ought to be there...
I've tried both ways a number of times. The only way I can do anything to
the drive in OS9 (without crashing or failed errors) is hooking the drive up
to the ATA card. In OSX I can format or reinitialize using FW (but have also
tried with the ATA hookup).
My PRAM-zapping hotkeys and CUDA button have been getting a serious workout
... ;).
This is a toughie alright. I do have one other thing to look at. A friend of mine bought a Orange Micro FW card to use under 9.1 on a 7500. Had all kinds of trouble because it used its own FW extension that was a p.o.s. Does your card use Apple's FW extension or use its own? If it has its own, is it conflicting with Apple's? Lastly, I seem to recall (way back) some people having problems with the FW authoring extension, disabled it and problems went away. I know that affects Toast, but maybe other FW stuff too? Grasping at straws here, but you may want to do the full blown Conflict Catcher routine and see if it isolates a system software issue. Worth a shot at this point...
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