Yuck. Hyperterminal sucks for this. We need to find something free and easy to use for grabbing boot logs. That log still has builder image stuff in it ("spinning down", "hdstress.cpp" etc) but also has developer image text in it. Personally I use a bought version of SecureCRT. SerialWatcher here is good for just capturing (I use it all the time when developing protocols for work) but isn't a terminal and as such won't let you issue commands at a shell prompt to fsck for example.

Anyway, it *looks* like the image is OK. Tried the fsck yet?

As far as I am aware the builder image works correctly on 80GB drives. I know it has problems with 100GB and higher. Perhaps, it created something incorrectly. Personally I built my 80GB by hand using Roger's instructions.