Disk /dev/hda: 255 heads, 63 sectors, 4864 cylinders
Units = cylinders of 16065 * 512 bytes

Oh, OK, panic over.

Your disk is configured as a small number of huge cylinders, not (as both mine are) a large number of small cylinders. In fact, your cylinder size is nearly 8Mb, so that's the granularity of your partition sizes. When the builder tries to make a 16Mb partition, it of course has to round up to the nearest cylinder -- two cylinders don't quite make 16Mb, so it uses three cylinders, or nearly 24Mb. (Likewise your "32Mb" partitions are nearly 40Mb.)

So whatever your problem is, it isn't this The response you got from the "dd" command indicates your disk is working fine. So if a clean install of 2.0final (with no third-party software, even Hijack) still does this, then I guess I'll have to find some time to bung you a copy with some more debugging enabled, and if there's a genuine problem we're looking at a 2.01 release...

Peter