I don't think its size, but rather the controller. I had the same
ptoblem with a HPT366 but then put in a HPT368 card and it runs great.
I was using a couple Maxrtor 36GB disks. The 368 is second version of
their ATA66 controller and apparently fixes some problems. I also have
a HPT374 (their ATA133 controller) that runs great. When getting add-in
IDE cards, stick to Highpoint. I tried a Promise card initially and
about once a month itd do the same thing after running great the rest
of the time, but it halts the CPU rather than nicely resetting the bus
when it has a problem.

>Hi,
>
>I just added an 80G Western Digital HD into my freebsd-stable box,
>which was recompiled on Tuesday. After I fdisk and disklabel it, I
>repeatedly get these errors on the console when the disk is under any
>load:
>
>ad6: READ command timeout tag=0 serv=0 - resetting
>
>After some time, the system locks up and a hard reset is required.
>
>The disk itself appears fine -- I've run it through the WD test tools and it
>has passed. I've installed it into a WinXP system with the exact same
>motherboard and HDD controller and ran tests, and it worked.
>
>The disk is a Western Digital 80G JB drive, with an 8M cache and a UDMA/133
>interface. It is installed on a Highpoint HPT-366 UDMA/66 controller
>integrated on my Abit BP6 motherboard. It is installed as the only device
>(as master) on the second IDE port of the controller.
>
>What could be causing these errors and lockups? The problem existed befre I
>recompiled on Tuesday. My previous build of 4.6-RC was done around May 3rd.
>
>Below is some hopefully useful info. If anything more is needed, or if I
>should try anything, please let me know.



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