Well, unlike the player image, there's no copyrighted data that would need to be included in a builder image, so this should be doable. Let's see. You'd need a kernel that had its root image on a ramdisk, the ramdisk itself containing a simple binary to do the following: create the partitions, turn on the swap partition, create the music filesystem, and burn in the filesystem, if desired. (I don't think we have to create the root filesystem, as the upgrade does that for us.) So the total things you'd need are the kernel, that init binary (or sh and a script, possibly), fdisk, swapon, mkfs, and dd and rm (or something to burn in with). Not a piece of even remotely copyrighted software there.

It looks to me like you have built a second drive, bigger than 40G, using the original builder image, and then cabled it in as slave.

When you add content to your player, the player distributes it across the disks it has available, and then records the meta data (tags, name, location etc) in the static database.

If you have simply shoved a new disk in in place of a dead second drive, it is now complaining that it can't find the tracks it expected to be there (from the old one).

You need to build this disk by hand using the instructions on Roger's website (www.differentpla.net) instead of using the builder. This will take a bit of command line magic using an installed developer image. You will then have to re-build the track database, which you can find in the FAQ.

a) empeg don't exist no more.

b) this would take motivation, something missing from the board these days.

c) Mark?