[blue68f100]

On servers where the OS is stored in flashram, this becomes a problem.
I believe the folowing models 1000v1, 2000, 4000, 4100 store the os in flashram. The reason for not needing a image file. If you need an image file to boot the server, reload the image file then try the upgrade to 805.

What else havn't we tried??????

Remove all drives.
format one with fat32 or ntsf since it a large drive.
Install into server. Does the server prepares/setup the drive for use?
If YES, your hosed. for v3 reload.
login to debug and enter the secret cmd "co de format 10000 /reinit"
then check for capacity.

I had one user it took several trys for it to take.
Have you tried a different brand drive (seagate). There have been some cases where one brand would not work, and another would. It has to do with the number of disk platters, heads and cylinder need for that particular capacity. On the 300 gigs, it can be done with 2 or 3 platers now. This makes a difference in how the lba setup. They will have diferent heads and cyl counts.

Just a thought.