I'll give that a try right now. I'll try installing the developer image and see what happens.

OK, I've just re-uploaded the consumer image 1.03 ('cause that was the one that was on the initial drive in the first place), re-attached the original disk and everything plays a-ok. This proves that there is nothing wrong with the player and that I didn't damage anything.

It just won't work with this new 48gig drive!
Maybe this car2.disk.builder thingie was never meant to be used on such big HD's?

I've actually found that Andygjones on this board posted the exact same error.
SMU speeded to his recue with a home-made procedure, but if possible I's rather not use it. Not because i don't want to but because of the disclaimer on the end.
You can read it here (I want to use the new HD as primary hd and the 10 gig as secondary)

Anybody else got a suggestion?

ps, can I install the developer image over the consumer image without ruining my hd's data?