@fitzsteve - Will give that a go, I have it connected with a cable tie which is a new addition, maybe something to do with that. Would like to get it sorted before I purchase any new CF Cards.
@Geit - No the cards haven't been cheap, usually stick to mainstream brands. The card out of the 500 I've been testing with has been fine for a couple of years just went to custard when trying to change the file system.
The Sandisk one wasn't cheap and it was a higher end card that's used in Cameras, but it only lasted a few months and now doesn't detect it, even on the PC.
So going to setup a standard laptop drive and use that, well that's when I get the ATA prefs to stick with no split and not keep going back to split when I restart LOL
All fun and games, just want to play a game now :-)