but now when I try to access the player through emplode it wants to check the disk integrity and it hangs there.

Did you hand-copy the files from the old 20 to the new 40? Using those shell commands you found in the upgrade guide?

If so, odds are you simply forgot to RO the disk drive before pulling the power, and it's doing a standard integrity check.

Note that when Emplode does an integrity check, it looks like it's hung, but it's not. It's just taking a long time. Those 40s take a long time to FSCK. You probably pulled the power without giving it a chance to finish the FSCK.

So you're probably at the point you need to do a manual FSCK.

This is, I think, the second or third time that someone's complained that emplode is locked up on "checking disk integrity", so that's 'frequent' enough for me to add a FAQ entry.