I finaly got it to work, seems it was the disks or the drive, I used a third drive I have and new disks and it worked. I was told the it is a basic IO error. Smoothwall is very cool, It takes a old pc and turns it into a realy nice router/firewall/gateway. It has all kinds of logs for firewall and does more than some of the "payfor" routers like linksys. and its free. I use dual dsl lines and need to use a nexland router to loadbalance them but I got hit by lightning and lost my nexland, so till I get a new one shipped in I needed to go back to useing my old smoothwall.
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