Thanks for the pointer, I've given it a try but still get this message intermittently on boot

Partition check:
hda:hda: set_geometry_intr: status=0x58
show_message("0000.0 hda: err: set_geometry_intr")

I've only got tiny CF cards at the moment so i'm not sure if that makes a difference.
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Mk2a 64mb 60gb