I don't mean to condescend, but have you tried re-downloading the
m0n0wall image? I've never had a problem using physdiskwrite :)
Quoting Jai Ketteridge <jai at innaloo dot net>:
> I have since redone the disk write process on my CF Cards using the windows
> utility physdiskwrite with the CF cards in the IDE adaptor instead of the
> Card Reader with exactly the same results - cant load kernel.
> Ive tried using DamnSmallLinux aswell - following the instructions and
> cfdisk reports a fatal error.
> I really dont know where to go with this next as I dont think CD rom and FDD
> is a good idea for a permanant firewall that will be hosted 4000km from
> where i live.
> Any other ideas guys?