Clone (instead of copying) wars.
I too had problems as a result (supposedly) of the filesystem on the internal microSD being cloned. I started putting down the Debian filesystem right before I went to bed. I found the errors when I got up. (It was a frustrating evening. I had local problems with my workstation too. Don't rely on grub if it is on the second disk.)
With the DreamPlug, I decided to start over and do it properly. Although I have a jtag, I took the microSD card out, repartitioned it and put the appropriate filesystems on it. I then added uImage to the first fat partition. Then I put the Debian filesystem on the second partition. It was much, much faster using my workstation to do this. Although it is in part because of the faster disk reading, the main reason is that there isn't nearly as much load on the system, and there is a lot more memory for caching.
After I put the microSD back in the DreamPlug, it booted Debian just fine. I'm now doing a dist-upgrade from lenny to stable. That seems to be going well, although the fat (ext3, actually) lady hasn't yet sung.
Other than that, it seems a really nifty item, and just what I wanted. (I'll get rid of the blinking lights, bluetooth and wifi.)
Best wishes,
Bob
PS Although I'm now just using the 2GB microSD, I also got a 8GB Class 10 SLC SD with my DreamPlug. My thought was to partition it and have 1GB swap, 3.5GB /var/www, 2GB /home and the rest /var/log/. This way the areas that get written to most will be on the faster, external, SD. Also, if needs be, the system will boot without the external SD in place.
RLF
PPS The fat lady has sung, and sweetly too. After the dist-upgrade to stable, I had no problem booting. It all looks good.
RLF
PPPS Once I got over the initial problem with the internal microSD, it was pretty straightforward.
sheevaplug-debian:~# df
Filesystem 1K-blocks Used Available Use% Mounted on
/dev/sda2 1787000 672760 1023464 40% /
tmpfs 256888 0 256888 0% /lib/init/rw
udev 10240 180 10060 2% /dev
tmpfs 256888 4 256884 1% /dev/shm
/dev/sdb2 3612272 491772 2936960 15% /var/www
/dev/sdb4 1217516 34840 1120828 4% /var/log
/dev/sda1 104226 2650 101576 3% /media/usb0
/dev/sdb3 2063536 35972 1922740 2% /home/rfrazier
tmpfs 256888 0 256888 0% /var/cache/apt
sheevaplug-debian:~# cat /etc/debian_version
6.0.1
sheevaplug-debian:~#
RLF