@ PaSha
Could a crappy power switch really cause all these problems? I'm no expert, but it seems like if it powers up, the power switch is working properly. Please explain - I know you're well-versed in this area :-)
HereBasically, the recycled-from-leftover-C64-stock power switch is prone to having bad connections, restricting the power flow (especially during higher loads). Replacing it with decent thickness links will usually cure any power-shortage related flakyness.
Your mileage may vary, but it's worth a shot.
According to
this a CD32 with SX32 Pro and a small 2.5" HD uses 2.19 Amps of +5vdc.
The lightweight type stock CD32 PSU is rated at 2.2 Amps of +5vdc, which is a bit too close to the limit.
The smaller, heavy stock CD32 PSU however, is rated at 3 Amps of +5vdc and should do the trick, as should an A590 PSU (3 Amps). The optimal solution is the lightweight A500 PSU, supplying a whopping 4.3 Amps of +5vdc (optimal because it doesn't have a fan).
-Paul