If he has a hardware error then rebuilding the disk isn't going to help !

It sounds more like the IDE headers or the cable starting to work lose.

Take a look at the advice here:

http://www.riocar.org/modules.php?op=modload&name=FAQ&file=index&myfaq=yes&id_cat=8&faqent=221#221

Don't run the disk builder.
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