I've been following the other threads regarding dual boot menu and problems with Diablo, and this does not appear to be the same thing.
In case it matters, this Diablo installation has been updated to the newest.

In the other threads, everyone mentions the progress bar going across the screen and a hard hang.

In my case, when I select the internal card I get no progress bar, but instead get the "Booting from ..." message and after about 10 seconds (maybe less), the screen clears and the device reboots.

My config is a 16GB SDHC carved up the way sfdisk likes it (I redefined the geometry the PC running linux fdisk saw as it caused sfdisk to complain) with 2GB vfat, 2.5GB ext3, 2.5GB ext3, 256MB swap, and the rest in another ext3 (the last two being logical partitions).

I downloaded the newest initfs_flasher from Fanoush's website and re-ran it (I'm pretty sure it's the same version I used before).
I even re-cloned the OS to a 2GB SD in case the SDHC was the problem.
No luck.

I finally started looking through the scripts to see how they work and I see that /mnt/initfs/linuxrc calls bootmenu.sh... so I looked into it further.
The linuxrc script loads several kernel modules, but it is specifying the path as /lib/modules/current, which does not exist!
Older firmwares had a link from "current" to "2.6.21-omap1" (the directory in which the modules actually reside).
I thought I had found the problem, so I modified the tarball whose contents are layered on top of the initfs during the build process, and it worked... but only so far as the proper link now exists in /mnt/initfs/lib/modules/current.
The boot menu still hangs when I try to boot to the internal memory card, then reboots.


Note that I've done the multi boot thing many times on the 770 and N800, and even wrote my own cloning scripts using both cpio and gtar... so I'm shocked that I haven't been able to figure this out on my own.

Thanks for any help or ideas you may be able to provide.