something possibly went wrong with your image burn. are your sure you are using the 512mb compact flash image.
make sure that the hdd is formatted completely. No partitions.
i was also thinking if we could possibly make a autorun cd that would burn the image to hdd using dd command as a shell executable script.
do you guys have any other ideas that we can work around.
PS:/ leaving for office now. will be uploading the iso in a couple of hours.