Okay this is driving me crazy - I hope anyone can help me out with this. Here's the situation:

I bought a SATA-to-IDE device so I could replace my loud 80GB drive with a 120GB SSD card. I know Windows 98 can handle drives up to 120GB so it seemed ideal.

After cloning the original drive to the SSD and reinstalling Windows 98 (wouldn't boot off the drive otherwise), I could enter Windows 98. The C partition was set to 8GB before the reinstall.

Windows 98 works fine, sees the 112GB partition fine as well. BUT. This PC doubles as a DOS PC for later DOS games and every time I want to boot in DOS, the entire PC hangs right when config.sys is done loading and it should load autoexec.bat. After about 5 minutes it continues but the D drive is unreadable. I tried resizing the partition to smaller and smaller sizes until even 2GB wouldn't load. If I remove the partition leaving just the 8GB C drive, it works fine.

Anyone have any idea why a second partition would cause this issue?