So ONLY real hardware problem was the WD hard drive controller. Glad you finally got the BB Happy.

Don't think I've ever come across an RLL hard drive that outlived it's controller card before.
You were talking about upgrading the ROM... just going up to the 1.3 ROM helps a lot, in that it allows autobooting and use of FFS for partitions.
Original FS on 1.2 only allows 56MB partitions or so. Just a heads up to get that SD adaptor working... Going straight up to 2.04 or 3.1 is a big culture shock if you've been used to 1.2 and 1.3. Mostly positive, I have to say.
Got mine going at last, on an A1200. Nice thing about FFS partitions - you can mount them on Linux systems, even write data to them if you set permissions. Makes file transfer a lot easier onto Amigas that don't have connectivity OR a compatible file system handy for file transfer.
OK, it's not perfect, flags on files sometimes messed up, so you have to set them manually. I downloaded the LHA.RUN file from Aminet, had to set it to "executable" to run the thing so I could extract lha archives on the Amiga side. Unextracting on Linux is very hit and miss, usually half or more of the data is missing.