I decided to put an internal hdd into my PBO (latest stock firmware). PBO asks to format drive - which I allow. It completes without errors, reboots, then asks to reformat again. I've done several rounds of formatting by PBO and it is never satisfied!

I removed drive and inserted into HDD enclosure and connected to a windows xp machine. It takes about 1 minute for XP to recognize it, and it will be visible in Windows Explorer. When I try to click on it to open and copy files, Windows says "This drive is not formatted, would you like to format it?"

I opened Windows Drive Management and the PBO is visible there. And it shows the standard 3 partitions that PBO creates when it formats the internal HDD. The only exception is that Drive Management shows them all as "Unknown Partition Type"

If I delete all these partitions and and format in windows, the drive is accessible. It certainly seems like a PBO issue, but I got the HDD for free from work, so...
I'm going to try and pickup another HDD today to double check, but any other thoughts? Seems like a few people have had to ship their units back to resolve similar issues.

Thanks in advance!