[sort of RESOLVED] Debian install on Sheeva: Making system bootable stuck at 33%

[narc]

Installing Debian Lenny on SheevaPlug.
I followed the installation guide at http://www.cyrius.com/debian/kirkwood/sheevaplug/install.html.
My U-Boot is upgraded.

For the second time on two different SD cards, my installer gets stuck at | Making the system bootable | at 33%.  This is after a successful installation last week but a kernel panic came along after an upgrade.  So I have to reinstall everything.

-  TFTP serving, loading and installing went well until | Making the system bootable |.

- I formated my 4GB SD card like so (in that order) 1) 50 mb for /boot, 2) 1G for swap and 3) the rest for /.  I also tried a 500 MB partition for boot.
Those numbers are just to give me some space since I was going to redirect swap and / to another disk.

- I also made sure that my /boot partition was bootable.

Is it presently formatting somehow ?

Any help appreciated.

[narc]

A follow up.

I successfully installed Lenny.  Instead of creating my partitions manually, I simply asked for an automated partition.
In the process, I had to remove the last two partitions definition - /tmp and /home - because the install couldn't create them and move ahead into the install process (a problem I already had with my previous successful installation, so apparently it's not an SD card thing).

This is what my new system is giving me now:

/dev/mmcblk0p1   *          33        7520      239616   83  Linux
Partition 1 does not end on cylinder boundary.
/dev/mmcblk0p2            7521       16064      273408   83  Linux
Partition 2 does not end on cylinder boundary.
/dev/mmcblk0p3           16096       80544     2062337    5  Extended
Partition 3 does not end on cylinder boundary.
/dev/mmcblk0p5           16097       57472     1324032   83  Linux
/dev/mmcblk0p6           57505       74016      528384   83  Linux
/dev/mmcblk0p7           74049       80544      207872   82  Linux swap / Solaris

I had numerous I/O errors on the first run, then after rebooting, dmesg was a lot cleaner.   I'm not quite sure about the cylinder boundary thing.  I will definitely hook up a USB drive for the main partitions.

Basically, I don't know what's the difference between the bootable partition it gave me and the one I created manually before.

It's automated partitionning for now on unless someone has a better explanation of what happened during my failed operations.