Thanks for the pointers Spud.
I'll try upgrading the mobo bios and the SATA driver. It's an ASUS mobo and XP doesn't even see the drive without the asus RAID driver installed. I don't think the drive will be on its last legs, as it's only 6 months old but given my 6 month old motherboard went pop - who knows?
Operator is a 13 year old kid, so operator error looks extremely likely.
