Tonight I started from the beginning with Roger's partitioning/formatting procedure,the new 80Gb drive set as slave.

There was one point where things didn't go as expected:
# mount -n /dev/hdc4 /drive1 - I received an error, something to do with mtab and already mounted (apologies for being so vague).
To 'get around' this I ran umount /drive1 and I was then able to complete the manual formatting guide.

Emplode was still bombing but now at the database stage rather than tags but still the same hex error code. [Along the way I have uninstalled my old Emplode, nuked hkey Current user\sonicblue[sic] from the registry and re-installed Emplode 2.0].

Remembering the manual database rebuild procedure, I thought I'd try to be clever so I set about creating these directories:
/drive0/var/database
/drive0/var/database3
/drive0/var/tags
/drive0/var/playlists

Emplode still crashes but now with 0xc0041015 - here's the serial console captured while sync'ing:
Adding Swap: 16028k swap-space (priority -1)
e2fsck 1.19, 13-Jul-2000 for EXT2 FS 0.5b, 95/08/09
ext2fs_check_if_mount: No such file or directory while determining whether /dev/
hda4 is mounted.
Restored terminal settings
Remounting first music partition read-only
Remounting second music partition read-only
No secondary hard disk
Restart code received
Starting playTimezone: Atlantic/South_Georgia
er
player.cpp : 385:empeg-car 2.01 2004/07/06.
! tags.cpp : 68:Failed to read tags: 0xc0041015.
Prolux 4 empeg car - 2.1434 Jul 5 2004
Vcb: 0x4054d000

This is the partition setup (looks OK to me):Code:

---

   Device Boot    Start       End    Blocks   Id  System
/dev/hda1             1         5     40131    5  Extended
/dev/hda2             6        10     40162+  83  Linux
/dev/hda3            11        13     24097+  10  OPUS
/dev/hda4            14      9729  78043770   83  Linux
/dev/hda5             1         3     24034+  83  Linux
/dev/hda6             4         5     16033+  82  Linux swap

---

Player is running 2.01, Hijack 268, current bootlog attached.