I have a similar problem. My external USB disk is named sdc on some bootups and 
sdg on others. I have a test (Karmic) system installed on this disk (I have now 
made Karmic my standard system on a fix internal drive but the problem still 
persists). It seems that during system initialization the USB memory card 
readers (SD, SF, etc), of which there are 4, are either given their 
designations before the USB disk, which then becomes sdg, or afterward, in 
which case the external disk becomes sdc. as a circumvention of the "cannot 
open..." error messages I use gparted to get the disk designations, then rename 
the pre-defined /boot/grub/device.map[-sdc or sdg] entry appropriate to the 
configuration.
I have attached hwinfo listings of the two configurations taken 15 minutes 
apart.

** Attachment added: "Good configuration"
   http://launchpadlibrarian.net/34710808/hwinfo-OK

-- 
update-grub reports error on inexistant device
https://bugs.launchpad.net/bugs/441301
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