Since the fsck I posted I have not re-blanked and re-copied.

My copying process is fairly simple:

I put Hijack on the player and then contact the player via WsFTP. I mount the drives RW by sending a site command. Then I open the drive0 fid's directory on the PC and the Empeg and select all the FIDs on the PC. I double check to make sure it's set to transfer the files in binary and then hit transfer. When it finishes, I do the same for drive1 (Normally this process takes about 3 days, it's a little over 110gb). Then I delete the drive0/var/database, playlists & tags. Mount the player RO and exit WsFTP. Reboot the player and let it do it's thing then sync in Emplode. Done

At this point, the problem player messes up the playlists, so I connect with WsFTP again, mount RW, delete drive0/var/palylists, database & tags and send over a copy of drive0/var/palylists, database & tags from my good player, then mount RO again and everything is happy!!!