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but when I add this new drive as drive 1, I can no longer access it! It doesn't make sense.

Unless somehow the player isn't recognizing both drives, and is using drive 1 as its primary disk.

In any case, there is something you might be able to do to help the database. I'm not certain if this will really work, but my fuzzy memory seems to tell me it might.

If your MP3s all have comments in their tags, pruning the comments out of each and every tag might squeak it under the RAM ceiling enough to allow a database rebuild.
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Tony Fabris