Does your old disk still work in it?
If you sent it to me I'm sure I could make it work with my box, but that doesn't mean it would work with yours
With a properly patched box the only stuff that should matter is:
1. Partition 1 is FAT32 PHTSYS containing the PhatBox operating system and other necessary files (which loading the 'firmware' puts there)
2. The first extended parition (4) is FAT32 PHTDTA containing a playlist with music so you can tell it's working
3. The drive is set to master
I might be able to help you if I cought you in IRC or something, but it's hard to troubleshoot something like this remotely...