Hi Nathan, forget the last post. I went through everything again including these:
sh-3.00# modprobe ieee80211_crypt_ccmp

sh-3.00# modprobe ieee80211_crypt

sh-3.00# modprobe ieee80211_crypt_tkip

sh-3.00# modprobe ieee80211_crypt_wep

sh-3.00# modprobe ieee80211

sh-3.00# /sbin/ipw3945d &
ipw3945d - regulatory daemon
Copyright (C) 2005-2006 Intel Corporation. All rights reserved.
version: 1.7.22
2007-06-10 08:47:45: ERROR: ipw3945d already running. If ipw3945d is not runnin g then you
need to remove '/var/run/ipw3945d.pid' and try again.
[1] 15355
[1] Done(1) /sbin/ipw3945d
sh-3.00# iwconfig eth1 key XXXXXXXXX
sh-3.00# iwconfig eth1 essid BTHomeHub-XXXX
sh-3.00# mount -o loop -t squashfs /zdrv_200.sfs /mnt/data
sh-3.00# modprobe ipw3945.ucode
FATAL: Module ipw3945.ucode not found.

The reg daemon started flashing the wifi light, and after putting everything in manually, I seem to have a full connection with the wifi light on steady. Usually, I can connect if this is on, but something is stopping it, and I think it is ipw3945.ucode, which does not load when I modprobe:

sh-3.00# modprobe ipw3945.ucode
FATAL: Module ipw3945.ucode not found.
sh-3.00#

It is in /lib/firmware/ipw3945.ucode so I do not know why it isnt loading.

I am so close! Any ideas?
Mike
EDIT: If I want it to start wifi during boot, will this work added to rc.local?
modprobe firmware_class
modprobe ieee80211_crypt_ccmp
modprobe ieee80211_crypt
modprobe ieee80211_crypt_tkip
modprobe ieee80211_crypt_wep
modprobe ieee80211
modprobe ipw3945d
modprobe ipw3945
modprobe ipw3945.ucode
/sbin/ipw3945d &
iwconfig eth1 key XXXXXX
iwconfig eth1 essid BTHomeHub-XXXX

edit2 I tried running the following script, after booting, my first ever!
It almost worked. Would it work if ipw3945.ucode loaded ok?
#!/bin/sh
# load firmware
modprobe firmware_class
# load some stuff. Dont know what this does
modprobe ieee80211_crypt_ccmp
modprobe ieee80211_crypt
modprobe ieee80211_crypt_tkip
modprobe ieee80211_crypt_wep
modprobe ieee80211
# load wifi regulatory daemon
modprobe ipw3945d
# load wifi driver
modprobe ipw3945
# load something that does not work yet
modprobe ipw3945.ucode
# start wifi regulatory daemon
/sbin/ipw3945d &
# configure wifi settings
iwconfig eth1 key XXXXXXXXXX
iwconfig eth1 essid BTHomeHub-XXXX
iwconfig eth1

Edit3 Just realised I have to run it twice. I guess the first time starts the daemon and you need to wait while it picks up the ip address before finishing the script. Probably got something in the wrong order. If run twice, it lights up the wifi light and puts eth1 into the wizard, but still no connection, and no ipw3945 driver listed in the wizard. ipw3945.ucode prob?

Hi Nathan,
Can't believe it but it is working!

I have to run the script twice and then use the wizard to get the ip address, so it looks like you will be able to put a working package together.

Guess it was my lack of experience that made it take so long. I suppose to make the script work, I would have to insert a pause somewhere while the daemon gets working and then something to pick up the ip address?

I am very happy now!

Cheers, Mike

EDIT - I have put the script into rc.local and added sleep 5

the network light comes on steady before the desktop comes up, so all I need to do is use the network wizard to get the ip address. I have tried to add the bits from net-setup.sh which grab the ip address, but cant seem to find the right bit.

Great, fantastic, and thanks for sticking to it until it started working

The file /lib/firmware/ipw3945.ucode is not a kernel module, but a piece of firmware. So there is no reason to modprobe it. That file should be picked up by the regulatory daemon provided it is in the correct location.

Not sure about how or when I'm going to get a patch out for this, I have to decide exactly how to put it all together first. As I mentioned, the binaries are all already present in the final iso's, it's just a matter of getting things initialised properly. It was mainly stuffed up by the fact that the firmware_class module should have been compiled into the kernel rather than as a module, but there are apparently a few other weak links as well. I'll have to re-examine everything. I want this to just be picked up automatically when the network wizard is run.

Nathan

Hi Nathan,its great to be able to use my favourite distro as my prime os at last!

yes that would be good to have eventually. I am quite happy for the moment with the script in rc.local, which now works a treat. I added the driver to rarsa's wizard and it now appears in the list, but does not save for the next boot, so at the moment, I have to run it just to pick up the ip address. I would like to add some script in rc.local that will pick up the ip address, and I guess I have to launch the dhcpcd client daemon. Do you know how to do this?
Cheers, Mike

If your interface is eth1, then this would be the command -
However, the wireless parameters must first be worked out if not done already.

Nathan

That bit was easy!
It is now online by the time the desktop comes up.
Thanks, Mike