here are some specs on the systems suffering the problems:
motherboard: iwill kk266+, iwill kk266+raid
cpu: athlon xp 2000, athlon xp 2100
chipset: kt133a/vt82c686b
onboard audio: cmi8738
isa soundcard: opti 82c924, crystal cs4232
primary storage: ide to sata ssd adapter, ide to cf adapter
via 4-in-1: 4.35v
the failure mode on the system with the cf adapter is very identifiable and repeatable. copying certain files from the onboard hpt370 raid array to certain areas on the os drive located on the cf adapter will cause that adapter to disconnect during the write and not be available until after a hard power cycle. the errors this generates on the fat32 file system can be unpredictable...sometimes completely recoverable by msdos scandisk where only the incomplete copied files are affected versus one time where half the folders under c:\program files were missing. very often there would be issues with invalid long file names which msdos scandisk would complain that only windows disk tools could repair. there always seemed to be audible crackling from my speakers to accompany the problematic file operations whenever vopl3 was installed.
once i found a set of particular files and a destination path that caused the problem i could repeat the failure on-demand over and over again. now, if i took the same set of files and copied them to an alternate destination path on the same drive then moved them to the original path it could work out just fine. something about the composition of source files and destination triggered the disconnects, but i could discern no pattern. file copies would just work until they didn't, but once i found a combination that didn't i could hammer it and get a failure absolutely every single time. needless to say, as soon as i uninstalled vopl3 all such combinations i identified would then successfully copy without issue.
the corruption on the system with the sata adapter was less tangible. twice, i had to reformat and restore because after a time windows would just eventually fail to boot displaying a windows protection error with no changes to the system. given how similar the 2 systems are i find it doubtful that something other than vopl3 is the culprit here despite no smoking gun. vopl3 is uninstalled now and so far so good after 5 days--i'll update this thread if that changes.
any ideas on why this might be happening on these specific systems? i really would like this to work on all my retro builds.