John, Looks like I am having the same problem as you. Box is patched, Original DMS works fine, Hack DMS doesn't work.
I'm using the VW system. I didn't try the manual method of patching, since the boot CD worked for me, and 'unlocked' the box. I did use the DD comand with the patch CD, for which I found instructions here on the forums. I've started over several times with the new HDD.
Recently Judb advised me to reformat the original PHTSYS partition, and load the firmware, and level 10 rcpairs. and create a bootload.log file. This didn't turn out any more verbose than berfore.
BOOT0-0: OK
BOOT0-1: OK
BOOT0: Successful
BOOT9: Successful
BOOTB: Successful
BOOTF: Successful
BOOT*: Successful
I was expecting more info than that. Should the rcpairs be overwritten, i assume?