I have the basic stuff that comes to mind already.... both ports on the IDE cable work using the good drive, tried all possible drive combinations/jumper settings (& 2nd drive always has problems). The player fails to boot using diskbuilder when the second drive is used alone or as the master. And the player boots with diskbuilder when the second drive is slaved to the good drive, but diskbuilder still fails rebuilding the second drive.

Sounds like it's time to contact support now since I am out of ideas....

Thanks, Mike.