though I gave up for the time being, I'd like to understand what you mean with this:
I suspect the kernel setting is not compatible with your distro setting [...]
Do you mean cbxbiker61's kernels are not suitable for the Ubuntu 9.04 version which comes with the plug? I've updated both the kernels in flash and on SD-card with his versions, where latter is the normal distro I'm using (booting from flash is only fallback). I'm considering to give the Debian Squeeze a chance and did some trial, however it will still take me some time to set it up properly and to migrate my existing setup .
You might want to look up udev that should fix this problem for you.
? udev is installed already ?
 luckily I have a second spare plug, which I bought to have a backup to be save if the first dies. I want to work in parallel on this one, but when done I just want to swap SD-cards (and amend/modify uboot-settings). I recall that the system "learns" it's MAC address and saves it somewhere, which needs to be deleted before moving cards, but I can't recall which file it is...