Once again everyone's help is sooooo much appreciated, I don't know where I'd be without all your guidance....!
Since my last post I've followed your advice and formatted the SD card *lots* of times. I first formatted it on one machine about 15 times and when I attempted to copy everything back onto the SD (using Select All > drag to SD) it kept erroring when it got to a particular file in bank2. Strange. The files I was trying to copy back had been copied off the SD card originally.
So I then formatted the SD on a different PC several times and attempted to copy the original files back again. Same thing, but with a different file. Hmm...starting to wonder at this point whether I have a duff SD card or a dodgy card reader perhaps.....
I then formatted it again lots of times and downloaded the original CF v4 sound font zip file from Plecterlabs, which then copies to the SD card fine without any errors. Progress!
So this morning before I headed off for work I did a quick test with the CF card. I've still got the latching switch only hooked up as a master power, in line between the batt and +ve, plus the speaker and Lux. I plonked the SD back in the board and successfully fired up the CF card about 10 times with the same result each time ie the Lux fires up and the saber ignite then hum play as they should. More progress!
Just got home from work and I've been testing it a bit more. Again it would fire up with the Lux & sounds time after time. I've then remove the SD card (with master power off) and re-inserted the card and a couple of 'problem' boots surface, about 5 in all one after the other. I then removed the card and re-inserted a couple of times and it settles again to the point where it will now fire up every time again unless I remove and re-insert the card. Seems almost like it's hit-n-miss as to whether the card seats properly.....possibly...
I've also identified one other prob in that my latching switch seems to be past its best, so I'm going to buy some new switches tomorrow and try those. I watched Erv's soldering tutorial last night and have identified a couple of solder joints that I need to re-do also.
I'll post back once I've had chance to do some more work/testing on it this weekend.
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