OK, updates.... I reversed the drive locations on the cable (but not the jumper/master/slave) and re-ran the fsck tests. Same errors, same drive (hdc). This led me to believe it may be the drive and not the cable. I also re-inspected the IDE header, and all looks good.

So, I ran the builder image (on each drive individually, in turn) and after running the format twice on each disk, got a format to complete successfully, and stress test returned no errors after ~30 minutes or so on each disk.

Next, I re-installed developer kernel 2.0, and re-ran fsck calls. Both disks ran without error! YAY right? hmm.. so I had read about the smartctl utility, and still suspect my hard disk may have a bad sector, so I installed Hijack 426, and copied the smartctl tool over.

All tests described here on HDA completed sucessfully, however I get the following error output on HDC:


empeg:/drive0/var# ./smartctl -s on /dev/hdc
smartctl version 5.33 [arm-empeg-linux-gnu] Copyright (C) 2002-4 Bruce Allen
Home page is http://smartmontools.sourceforge.net/

Warning! Drive Identity Structure error: invalid SMART checksum.
=== START OF ENABLE/DISABLE COMMANDS SECTION ===
SMART Enabled.

empeg:/drive0/var# ./smartctl -l error /dev/hdc
smartctl version 5.33 [arm-empeg-linux-gnu] Copyright (C) 2002-4 Bruce Allen
Home page is http://smartmontools.sourceforge.net/

Warning! Drive Identity Structure error: invalid SMART checksum.
=== START OF READ SMART DATA SECTION ===
SMART Error Log Version: 1
Warning: ATA error count 0 inconsistent with error log pointer 4

ATA Error Count: 0
CR = Command Register [HEX]
FR = Features Register [HEX]
SC = Sector Count Register [HEX]
SN = Sector Number Register [HEX]
CL = Cylinder Low Register [HEX]
CH = Cylinder High Register [HEX]
DH = Device/Head Register [HEX]
DC = Device Command Register [HEX]
ER = Error register [HEX]
ST = Status register [HEX]
Powered_Up_Time is measured from power on, and printed as
DDd+hh:mm:SS.sss where DD=days, hh=hours, mm=minutes,
SS=sec, and sss=millisec. It "wraps" after 49.710 days.

Error 0 occurred at disk power-on lifetime: 0 hours (0 days + 0 hours)
When the command that caused the error occurred, the device was in an unknown state.

After command completion occurred, registers were:
ER ST SC SN CL CH DH
-- -- -- -- -- -- --
51 0e 03 00 ce 89 dd at LBA = 0x0d89ce00 = 227134976

Commands leading to the command that caused the error were:
CR FR SC SN CL CH DH DC Powered_Up_Time Command/Feature_Name
-- -- -- -- -- -- -- -- ---------------- --------------------
40 20 0c 02 00 00 00 50 12d+10:16:38.403 READ VERIFY SECTOR(S)
00 00 00 00 00 00 00 00 00:00:56.579 NOP [Abort queued commands]

Error -1 occurred at disk power-on lifetime: 0 hours (0 days + 0 hours)
When the command that caused the error occurred, the device was in an unknown state.

After command completion occurred, registers were:
ER ST SC SN CL CH DH
-- -- -- -- -- -- --
ce 89 f0 51 03 00 ce Error: ABRT

Commands leading to the command that caused the error were:
CR FR SC SN CL CH DH DC Powered_Up_Time Command/Feature_Name
-- -- -- -- -- -- -- -- ---------------- --------------------
00 ce 50 20 8b 05 00 89 00:00:16.384 NOP [Reserved subcommand]
00 00 00 00 00 00 00 00 00:00:00.000 NOP [Abort queued commands]

Error -2 occurred at disk power-on lifetime: 0 hours (0 days + 0 hours)
When the command that caused the error occurred, the device was in an unknown state.

After command completion occurred, registers were:
ER ST SC SN CL CH DH
-- -- -- -- -- -- --
dd 00 89 ce f0 51 03

Commands leading to the command that caused the error were:
CR FR SC SN CL CH DH DC Powered_Up_Time Command/Feature_Name
-- -- -- -- -- -- -- -- ---------------- --------------------
02 dd 89 ce 50 20 ae 03 12:29:17.696 [RESERVED]

Error -3 occurred at disk power-on lifetime: 0 hours (0 days + 0 hours)
When the command that caused the error occurred, the device was active or idle.

After command completion occurred, registers were:
ER ST SC SN CL CH DH
-- -- -- -- -- -- --
40 51 03 dd 89 ce f0 Error: UNC at LBA = 0x00ce89dd = 13535709

Commands leading to the command that caused the error were:
CR FR SC SN CL CH DH DC Powered_Up_Time Command/Feature_Name
-- -- -- -- -- -- -- -- ---------------- --------------------
20 00 03 dd 89 ce 50 00 6d+06:35:14.519 READ SECTOR(S)

Error -4 occurred at disk power-on lifetime: 0 hours (0 days + 0 hours)
When the command that caused the error occurred, the device was in an unknown state.

After command completion occurred, registers were:
ER ST SC SN CL CH DH
-- -- -- -- -- -- --
00 03 ce 89 dd 0e 8a

Commands leading to the command that caused the error were:
CR FR SC SN CL CH DH DC Powered_Up_Time Command/Feature_Name
-- -- -- -- -- -- -- -- ---------------- --------------------
dc a6 03 00 00 40 04 c9 42d+17:21:42.537 BOOT POST-BOOT [RET-4]
dc 00 00 00 00 00 04 00 42d+17:21:42.537 BOOT POST-BOOT [RET-4]

empeg:/drive0/var#



SO, any ideas?
Seems odd about the "Warning! Drive Identity Structure error: invalid SMART checksum." message? was it a download problem on the executable?

what do you think now? still a cable or other problem?

I'm going to try another hard disk, and go back through the builder/developer/fsck/smartctl tests again...

thanks for all the support guys!
Thunder