Much testing later (if I never see HDToolbox again, it will be too soon
The dev. board seems fairly stable, however using HDF files > 4000MB seems to cause an issue when partitioning.
Creating a partition of around 4000MB on a 4GB (real 4GB size, not HDD manufacturer rounded off size) caused the install31.adf file to become corrupt!
There would seem to be some kind of overflow issue in the firmware? Or possibly some FAT32 issue when nearing the final border of FAT32 file size?
Further: cutting the HDF file down to 4000MB and then partitioning prevents this issue.
However I cannot create partitions which will correctly format when then partition size is > ~1900MB in size.
(I tried MANY different sizes from about 1990MB down to 1950MB, then 1900MB succeeded).
I need to do a side-by-side comparison with my other stock minimig to see if this is an issue.
I am assuming some kind of problem with FFS / the 3.1 disk formatter as once a stable partition is created I have no issues.
I tested the 1900MB partition with a full 3.1 install and all seems good.
Am I running into known issues here? Are there some disk test programs or other tests I could run?
Any other suggestions from the experts?