For my half-penny-worth on this...

I see the 'Out of Disk' error message on cold or warm boot of 10.04...
it sits for a few seconds and then flashes up a 'timeout' message before
it goes on to boot.

This is on an HP NC4400, clean install from the live CD image onto a big
SATA hard disk, stock partitioning (i.e. / is most of the disk and there
is an extended partition providing swap space). On the initial build the
'out of disk' was stopping the run but (I think, it was months ago)
removing the recordfail check in /etc/grub.d/10* prevented that
happening and allowed the system to boot.

I 'just' accepted the patch that introduced kernel 2.6.32-30 and now the
system shows the 'out of  disk' and carries on after a few seconds.

I have 10.04 installed on virtual machines at work, running in Virtual
Box on XP and none of these have ever had the issue... nor does a work
Dell laptop (a Dimension M4300) running 10.04 stock. This appears to be
a hardware-specific issue... not related to USB connected disks or to
IDE/CF exclusively.

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https://bugs.launchpad.net/bugs/477430

Title:
  grub 2 error: out of disk. failed to boot default entries. press any
  key to continue...

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