In reply to:

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Best way to sort out if it's a flakey drive is to post a serial log of the boot/during operation.

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I assume you mean while it's in the car. I'll have to hook up my laptop to it this weekend and record it. (Unless you mean an AC bootup log, in which I can get one right now..)

I will check all the obviouses, tonight after work. It's never been opened (funny enough, the one that does NOT have an issue HAS been opened up and had a second drive added by moi.)

Thanks!
Mike.