I know what the problem is - the VW/Audi boxes WILL NOT play a list that does not have a VALID voice tag.
The fix is to go ahead and do the patch thing with the disk, but BEFORE you insert the disk in the Phatbox, open PHTDTA on your windows machine.
Open the PROFILES directory. Inside there is a file called "Profiles". Open that in wordpad.
The first stanza in there reads:
[Default]
num_discs=2
startup_sound=
pattern=$Artist$ - $Title$
The only line of interest is the third inside (soe of the others may be slightly different) the "Default" stanza, which reads "startup_sound=".
Change that to read:
startup_sound=/dos/data/music/flactemp.flac
Save the file.
Now check PHTDTA for a directory called "Music" (case doesn't matter, its DOS) Inside there should be a file (from the patch disk) called "flactemp.flac".
If there is, you're all set.
Go insert the DMS into the Phatbox, then turn it on.
There will be NO indication that anything has happened when the box starts up. Let 30 seconds or so of the first song that plays go by, then turn it off.
Wait for the RED LIGHT on the Phatbox to go out, and remove the DMS.
Put it back in your PC cradle and open PHTSYS.
There should be a directory in there called "log".
Look inside there.
If there are multiple files OTHER THAN "logs-go-here" or "logshere", then the patch process EXECUTED and your box should be unlocked.
If there are NO files in there (other than those two aforementioned files - only one of them may be present, or both) then the patch DID NOT run.
If the files are NOT present, post back here. If they ARE, then go ahead and swap in the new disk.
Remember once you put the new disk in the holder that you MUST go into PMM and tell it to update the firmware on the NEW DMS (the one with the "bogus" disk). This is NECESSARY because the new cartridge has NO firmware on it!
Once you have done that, you probably want to remove the file "foreceupdate" from the PHTSYS folder, since your box doesn't need its firmware updated.
Now go insert the "cloned" DMS into the Phatbox, and it should work.
I had to hack around to get the VW/Audi boxes to unlock, and can help you get it working. I have a 60gb un-branded Samsung disk working in my Jetta right now - its not difficult, but does require a bit of manual manipulation.