Thanks for the info sven. I had gone through the upgrade procedure you mentioned and the error occured at step 5: Apply the "builder-image" upgrade to your empeg (right at the end of pumping the partition).

However it seems that although it gave the error at the end, the builder software had actually created the partitions on the new disk, so i have all the required partitions (6 of them). It just wouldnt boot up and run the format.

In the end i had to apply the developer software to the new disk, run mke2fs and create the required directories.

Still have no idea why i was getting this error but it all seems to be working ok now and emplode picks up the extra drive and synchronises fine.

Thanks for your help

andy

RioCar 10GB RGB - can never decide