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Does anybody have a clue what's going on?
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Yes. It's all about what GRUB thinks the drive numbers are. I think that mixing SATA and PATA might muddy the water, but I'm not clear on exactly how.
Suppose the second SATA was being seen by GRUB as hd3. Adding the DVD to the PATA chain likely changes that.
You can see GRUB's version of reality by starting the GRUB shell and entering the command "root (hdX,Y)" X = 1, 2 , 3...etc.) It will respond with what is on each drive/partition)
Once you know how GRUB is seeing the drives, you can edit /boot/grub/menu.lst to match.