Ok I'm now the happy owner of a working hacked 80G DMS
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The solution in the end I got through reading some of judb's other posts was as mundane as it was effective.. I formatted PHTSYS, started with a fresh set of firmware (removed the forceupdate file) and I was up and running.
Thanks to all who put the effort in to get this hack going in the 1st place
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Cheers.