OK, here I go again
Not sure whether a floating RAS connection on the chips can cause problems or not. When debugging the >32MB kernel issue on a 48MB player it seemed as though I needed to tie unused banks high to avoid them asserting data lines when they shouldn't. When I did my 64MB upgrade I stupidly forgot to upgrade my kernel first, resulting in my needing to deactivate two banks to get below 32MB so that I could upgrade, and in that case I didn't need to tie those two banks high. Go figure.
This non-boot problem can be caused by address bus errors preventing the flash from being read, so that's somewhere else to check should the problem be non-obvious.
Good luck.