Greetings!

Indeed. The bug in the builder software is no different based on the size of the drive. I have seen it on everything from 10GB through 80GB drives.

The fact that it ran through a second time without any intervention (did you have to hit a return through hyperterminal?) actually means that it did fail the first time, but worked the second...

Since you can load music and sync, I would not even worry about it. Download the most recent copy of hijack and load it up for yourself. Enjoy!