From: "Henk Zomer" <henk dot zomer at hetnet dot nl>

> On 1 of my other computers which is capable to boot fro a cd, I removed 
> the
> second HD and replaced it by the HD on which M0n0wall is supposed to run.
> This one has been formatted in FAT32 and is empty.

> Then I used your installer CD as boot cd.
> So far so good.

> atacontrol list works; second HD is recognized as SEagate which is ok.
> Then I applied this command in 1 line:

> gzcat /usr/m0n0wall/generic-pc-1.11.img | dd of=/dev/ad1 bs=16k

> then appears the message that the disk is full....

Take a disk, and hook it up slave on your own modern desktop.  Boot into 
windowsXP and use physdiskwrite to write the image.  I usually juice a few 
drives at a time.  Slap one in that troublesome system.  If it fails, it is 
an issue with that system.  I have an old HP PPro server that will give 
"Read Error" and a hard drive, but boot a CD.  Never bothered to figure out 
why.

                            Lee