Otto Moerbeek wrote
> 
> Thanks for the report, but please also provide the output of fdisk.
> We are working on a more strict mbr validation, but this is all quite
> tricky and will take some iterations to get right. 
> 
This thing seems to be aimed at reading my mind.
Not what is IN my mind, but what SHOULD BE in my mind.
Loverly if you can pull it off.

Upgrade USB stick (sdb) on Lenovo T60 gives: (there may be typos)
Available disks are: sd0 sd1.
Which one is the root disk? (or 'done') [sd0] sd1
Root filesystem? [sd1a]
Checking root filesystem (fsck -fp /dev/sd1a)...OK.
Mounting root file system (mount -o ro /dev/sd1a /mnt)...OK.
DHCPREQUEST on em0 to 255.255.255.255 port 67
DHCPACK from 192.168.2.1 (00:11:50:72:b5:ac)
bound to 192.168.2.12 -- renewal in 905174339 seconds.
Do you want to do any manual network configuration? [no]
Force checking of non-root filesystems? [yes] no
fsck -p /dev/sd0a...1 is after 0, ok
2 is after 0, ok
0 is before 1, ok
2 is after 1, ok
0 is before 2, ok
1 is before 2, ok
1 is after 0, ok
2 is after 0, ok
0 is before 1, ok
2 is after 1, ok
0 is before 2, ok
1 is before 2, ok
FAILED. You must fsck /dev/sd0a manually.
#

Cause:
upgrade on T60 where sd1 is OpenBSD USB flash drive 
   and sd0 is the NTFS hard drive.
Install was on T41 where sd0 is OpenBSD flash drive 
   and wd0 is the NTFS hard drive.
Something got confused. Understandably.
Holds together remarkably well, considering!
Looks like I need TWO flash drives: for sd0a and for sd1a.

following are dmesg fdisk and disklabel for T60 and T41

T60 dmesg
OpenBSD 4.5-current (RAMDISK_CD) #148: Wed May 13 12:44:58 MDT 2009
    dera...@i386.openbsd.org:/usr/src/sys/arch/i386/compile/RAMDISK_CD
cpu0: Intel(R) Core(TM)2 CPU T5500 @ 1.66GHz ("GenuineIntel" 686-class) 1.67
GHz
cpu0:
FPU,V86,DE,PSE,TSC,MSR,PAE,MCE,CX8,APIC,SEP,MTRR,PGE,MCA,CMOV,PAT,PSE36,CFLU
SH,DS,ACPI,MMX,FXSR,SSE,SSE2,SS,HTT,TM,SBF,SSE3,MWAIT,DS-CPL,EST,TM2,CX16,xT
PR
real mem  = 1063677952 (1014MB)
avail mem = 1021804544 (974MB)
mainbus0 at root
bios0 at mainbus0: AT/286+ BIOS, date 09/29/06, BIOS32 rev. 0 @ 0xfd6b0,
SMBIOS rev. 2.4 @ 0xe0010 (68 entries)
bios0: vendor LENOVO version "79ETC1WW (2.01 )" date 09/29/2006
bios0: LENOVO 1953DDU
acpi0 at bios0: rev 2
acpi0: tables DSDT FACP SSDT ECDT TCPA APIC MCFG HPET BOOT SSDT SSDT SSDT
SSDT
acpimadt0 at acpi0 addr 0xfee00000: PC-AT compat
cpu0 at mainbus0: apid 0 (boot processor)
cpu0: apic clock running at 166MHz
cpu at mainbus0: not configured
ioapic0 at mainbus0: apid 1 pa 0xfec00000, version 20, 24 pins
ioapic0: misconfigured as apic 2, remapped to apid 1
acpiprt0 at acpi0: bus 0 (PCI0)
acpiprt1 at acpi0: bus -1 (AGP_)
acpiprt2 at acpi0: bus 2 (EXP0)
acpiprt3 at acpi0: bus 3 (EXP1)
acpiprt4 at acpi0: bus 4 (EXP2)
acpiprt5 at acpi0: bus 12 (EXP3)
acpiprt6 at acpi0: bus 21 (PCI1)
bios0: ROM list: 0xc0000/0xea00! 0xcf000/0x1000 0xd0000/0x1000
0xdc000/0x4000! 0xe0000/0x10000!
pci0 at mainbus0 bus 0: configuration mode 1 (bios)
pchb0 at pci0 dev 0 function 0 "Intel 82945GM Host" rev 0x03
vga1 at pci0 dev 2 function 0 "Intel 82945GM Video" rev 0x03
wsdisplay0 at vga1 mux 1: console (80x25, vt100 emulation)
"Intel 82945GM Video" rev 0x03 at pci0 dev 2 function 1 not configured
"Intel 82801GB HD Audio" rev 0x02 at pci0 dev 27 function 0 not configured
ppb0 at pci0 dev 28 function 0 "Intel 82801GB PCIE" rev 0x02: apic 1 int 20
(irq 11)
pci1 at ppb0 bus 2
em0 at pci1 dev 0 function 0 "Intel PRO/1000MT (82573L)" rev 0x00: apic 1
int 16 (irq 11), address 00:15:58:7d:ad:11
ppb1 at pci0 dev 28 function 1 "Intel 82801GB PCIE" rev 0x02: apic 1 int 21
(irq 11)
pci2 at ppb1 bus 3
wpi0 at pci2 dev 0 function 0 "Intel PRO/Wireless 3945ABG" rev 0x02: apic 1
int 17 (irq 11), MoW1, address 00:18:de:b0:54:13
ppb2 at pci0 dev 28 function 2 "Intel 82801GB PCIE" rev 0x02: apic 1 int 22
(irq 11)
pci3 at ppb2 bus 4
ppb3 at pci0 dev 28 function 3 "Intel 82801GB PCIE" rev 0x02: apic 1 int 23
(irq 11)
pci4 at ppb3 bus 12
uhci0 at pci0 dev 29 function 0 "Intel 82801GB USB" rev 0x02: apic 1 int 16
(irq 11)
uhci1 at pci0 dev 29 function 1 "Intel 82801GB USB" rev 0x02: apic 1 int 17
(irq 11)
uhci2 at pci0 dev 29 function 2 "Intel 82801GB USB" rev 0x02: apic 1 int 18
(irq 11)
uhci3 at pci0 dev 29 function 3 "Intel 82801GB USB" rev 0x02: apic 1 int 19
(irq 11)
ehci0 at pci0 dev 29 function 7 "Intel 82801GB USB" rev 0x02: apic 1 int 19
(irq 11)
usb0 at ehci0: USB revision 2.0
uhub0 at usb0 "Intel EHCI root hub" rev 2.00/1.00 addr 1
ppb4 at pci0 dev 30 function 0 "Intel 82801BAM Hub-to-PCI" rev 0xe2
pci5 at ppb4 bus 21
cbb0 at pci5 dev 0 function 0 "TI PCI1510 CardBus" rev 0x00: apic 1 int 16
(irq 11)
cardslot0 at cbb0 slot 0 flags 0
cardbus0 at cardslot0: bus 22 device 0 cacheline 0x8, lattimer 0xb0
pcmcia0 at cardslot0
ichpcib0 at pci0 dev 31 function 0 "Intel 82801GBM LPC" rev 0x02: PM
disabled
pciide0 at pci0 dev 31 function 1 "Intel 82801GB IDE" rev 0x02: DMA, channel
0 configured to compatibility, channel 1 configured to compatibility
atapiscsi0 at pciide0 channel 0 drive 0
scsibus0 at atapiscsi0: 2 targets
cd0 at scsibus0 targ 0 lun 0: <HL-DT-ST, RW/DVD GCC-4247N, 1.01> ATAPI
5/cdrom removable
cd0(pciide0:0:0): using PIO mode 4, Ultra-DMA mode 2
pciide0: channel 1 ignored (disabled)
ahci0 at pci0 dev 31 function 2 "Intel 82801GBM AHCI" rev 0x02: apic 1 int
16 (irq 11), AHCI 1.1
scsibus1 at ahci0: 32 targets
sd0 at scsibus1 targ 0 lun 0: <ATA, HITACHI HTS72201, DC2Z> SCSI3 0/direct
fixed
sd0: 95396MB, 512 bytes/sec, 195371568 sec total
"Intel 82801GB SMBus" rev 0x02 at pci0 dev 31 function 3 not configured
usb1 at uhci0: USB revision 1.0
uhub1 at usb1 "Intel UHCI root hub" rev 1.00/1.00 addr 1
usb2 at uhci1: USB revision 1.0
uhub2 at usb2 "Intel UHCI root hub" rev 1.00/1.00 addr 1
usb3 at uhci2: USB revision 1.0
uhub3 at usb3 "Intel UHCI root hub" rev 1.00/1.00 addr 1
usb4 at uhci3: USB revision 1.0
uhub4 at usb4 "Intel UHCI root hub" rev 1.00/1.00 addr 1
isa0 at ichpcib0
isadma0 at isa0
pckbc0 at isa0 port 0x60/5
pckbd0 at pckbc0 (kbd slot)
pckbc0: using irq 1 for kbd slot
wskbd0 at pckbd0: console keyboard, using wsdisplay0
npx0 at isa0 port 0xf0/16: reported by CPUID; using exception 16
rd0: fixed, 3800 blocks
umass0 at uhub0 port 2 configuration 1 interface 0 "USB DISK 2.0" rev
2.00/10.29 addr 2
umass0: using SCSI over Bulk-Only
scsibus2 at umass0: 2 targets, initiator 0
sd1 at scsibus2 targ 1 lun 0: <USB, DISK 2.0, 1029> SCSI0 0/direct removable
sd1: 1944MB, 512 bytes/sec, 3981312 sec total
"STMicroelectronics Biometric Coprocessor" rev 1.00/0.01 addr 2 at uhub4
port 2 not configured
uhidev0 at uhub1 port 1 configuration 1 interface 0 "Microsoft Microsoft
3-Button Mouse with IntelliEye(TM)" rev 1.10/3.00 addr 2
uhidev0: iclass 3/1
uhid at uhidev0 not configured
softraid0 at root
1 is after 0, ok
2 is after 0, ok
0 is before 1, ok
2 is after 1, ok
0 is before 2, ok
1 is before 2, ok
root on rd0a swap on rd0b dump on rd0b
1 is after 0, ok
2 is after 0, ok
0 is before 1, ok
2 is after 1, ok
0 is before 2, ok
1 is before 2, ok
1 is after 0, ok
2 is after 0, ok
0 is before 1, ok
2 is after 1, ok
0 is before 2, ok
1 is before 2, ok
1 is after 0, ok
2 is after 0, ok
0 is before 1, ok
2 is after 1, ok
0 is before 2, ok
1 is before 2, ok
1 is after 0, ok
2 is after 0, ok
0 is before 1, ok
2 is after 1, ok
0 is before 2, ok
1 is before 2, ok
1 is after 0, ok
2 is after 0, ok
0 is before 1, ok
2 is after 1, ok
0 is before 2, ok
1 is before 2, ok
1 is after 0, ok
2 is after 0, ok
0 is before 1, ok
2 is after 1, ok
0 is before 2, ok
1 is before 2, ok

--- 2 or 3 attempts in there

Disk: sd0       geometry: 193821/16/63 [195371568 Sectors]
Offset: 0       Signature: 0xAA55
            Starting         Ending         LBA Info:
 #: id      C   H   S -      C   H   S [       start:        size ]
----------------------------------------------------------------------------
---
*0: 07      0   1   1 - 106784  15  63 [          63:   107639217 ] NTFS

 1: 12 106785   0   1 - 116264  15  63 [   107639280:     9555840 ] Compaq
Diag.
 2: 07 116265   0   1 - 193814  15  63 [   117195120:    78170400 ] NTFS

 3: 00      0   0   0 -      0   0   0 [           0:           0 ] unused


Disk: sd1       geometry: 247/255/63 [3981312 Sectors]
Offset: 0       Signature: 0xAA55
            Starting         Ending         LBA Info:
 #: id      C   H   S -      C   H   S [       start:        size ]
----------------------------------------------------------------------------
---
 0: 00      0   0   0 -      0   0   0 [           0:           0 ] unused

 1: 00      0   0   0 -      0   0   0 [           0:           0 ] unused

 2: 00      0   0   0 -      0   0   0 [           0:           0 ] unused

*3: A6      0   1   1 -    246 254  63 [          63:     3967992 ] OpenBSD

# /dev/rsd1c:
type: SCSI
disk: SCSI disk
label: DISK 2.0        
flags:
bytes/sector: 512
sectors/track: 63
tracks/cylinder: 255
sectors/cylinder: 16065
cylinders: 247
total sectors: 3981312
rpm: 3600
interleave: 1
trackskew: 0
cylinderskew: 0
headswitch: 0           # microseconds
track-to-track seek: 0  # microseconds
drivedata: 0 

16 partitions:
#                size           offset  fstype [fsize bsize  cpg]
  a:          3800000               63  4.2BSD   2048 16384    1 
  b:           167992          3800063    swap                   
  c:          3981312                0  unused                   

----Following is same flash drive on T41 after successful upgrade----
OpenBSD 4.5-current (GENERIC) #0: Wed May 13 12:28:46 MDT 2009
    dera...@i386.openbsd.org:/usr/src/sys/arch/i386/compile/GENERIC
cpu0: Intel(R) Pentium(R) M processor 1600MHz ("GenuineIntel" 686-class)
1.60 GHz
cpu0:
FPU,V86,DE,PSE,TSC,MSR,MCE,CX8,SEP,MTRR,PGE,MCA,CMOV,PAT,CFLUSH,DS,ACPI,MMX,
FXSR,SSE,SSE2,TM,SBF,EST,TM2
real mem  = 804220928 (766MB)
avail mem = 768774144 (733MB)
mainbus0 at root
bios0 at mainbus0: AT/286+ BIOS, date 06/02/06, BIOS32 rev. 0 @ 0xfd750,
SMBIOS rev. 2.33 @ 0xe0010 (61 entries)
bios0: vendor IBM version "1RETDPWW (3.21 )" date 06/02/2006
bios0: IBM 23737FU
apm0 at bios0: Power Management spec V1.2
apm0: battery life expectancy 100%
apm0: AC on, battery charge high
acpi at bios0 function 0x0 not configured
pcibios0 at bios0: rev 2.1 @ 0xfd6e0/0x920
pcibios0: PCI IRQ Routing Table rev 1.0 @ 0xfdea0/272 (15 entries)
pcibios0: PCI Interrupt Router at 000:31:0 ("Intel 82371FB ISA" rev 0x00)
pcibios0: PCI bus #6 is the last bus
bios0: ROM list: 0xc0000/0x10000 0xd0000/0x1000 0xd1000/0x1000
0xdc000/0x4000! 0xe0000/0x10000
cpu0 at mainbus0: (uniprocessor)
cpu0: Enhanced SpeedStep 1600 MHz (1484 mV): speeds: 1600, 1400, 1200, 1000,
800, 600 MHz
pci0 at mainbus0 bus 0: configuration mode 1 (bios)
io address conflict 0x5800/0x8
io address conflict 0x5808/0x4
io address conflict 0x5810/0x8
io address conflict 0x580c/0x4
extent `pciio' (0x0 - 0xffffffff), flags=0
     0x1800 - 0x186f
     0x1880 - 0x189f
     0x18c0 - 0x18ff
     0x1c00 - 0x1cff
     0x2000 - 0x207f
     0x2400 - 0x24ff
     0x3000 - 0x8fff
     0x10000 - 0xffffffff
extent `pcimem' (0x0 - 0xffffffff), flags=0
     0x1000 - 0x9ffff
     0xd2000 - 0xd3fff
     0xdc000 - 0x2ff78fff
     0x2ff80000 - 0x300003ff
     0xc0000000 - 0xc00003ff
     0xc0000800 - 0xc00008ff
     0xc0000c00 - 0xc0000dff
     0xc0100000 - 0xefffffff
     0xff800000 - 0xffffffff
pchb0 at pci0 dev 0 function 0 "Intel 82855PM Host" rev 0x03
intelagp0 at pchb0
agp0 at intelagp0: aperture at 0xd0000000, size 0x10000000
ppb0 at pci0 dev 1 function 0 "Intel 82855PM AGP" rev 0x03
pci1 at ppb0 bus 1
extent `ppb0 pciio' (0x0 - 0xffffffff), flags=0
     0x0 - 0x30ff
     0x4000 - 0xffffffff
extent `ppb0 pcimem' (0x0 - 0xffffffff), flags=0
     0x0 - 0xc010ffff
     0xc0200000 - 0xffffffff
vga1 at pci1 dev 0 function 0 "ATI Radeon Mobility M7" rev 0x00
wsdisplay0 at vga1 mux 1: console (80x25, vt100 emulation)
wsdisplay0: screen 1-5 added (80x25, vt100 emulation)
radeondrm0 at vga1: irq 11
drm0 at radeondrm0
uhci0 at pci0 dev 29 function 0 "Intel 82801DB USB" rev 0x01: irq 11
uhci1 at pci0 dev 29 function 1 "Intel 82801DB USB" rev 0x01: irq 11
uhci2 at pci0 dev 29 function 2 "Intel 82801DB USB" rev 0x01: irq 11
ehci0 at pci0 dev 29 function 7 "Intel 82801DB USB" rev 0x01: irq 11
usb0 at ehci0: USB revision 2.0
uhub0 at usb0 "Intel EHCI root hub" rev 2.00/1.00 addr 1
ppb1 at pci0 dev 30 function 0 "Intel 82801BAM Hub-to-PCI" rev 0x81
pci2 at ppb1 bus 2
mem address conflict 0xb0000000/0x1000
mem address conflict 0xb1000000/0x1000
extent `ppb1 pciio' (0x0 - 0xffffffff), flags=0
     0x0 - 0x3fff
     0x8000 - 0x803f
     0x9000 - 0xffffffff
extent `ppb1 pcimem' (0x0 - 0xffffffff), flags=0
     0x0 - 0xc020ffff
     0xc0214000 - 0xc0214fff
     0xc0220000 - 0xc023ffff
     0xd0000000 - 0xffffffff
cbb0 at pci2 dev 0 function 0 "TI PCI4520 CardBus" rev 0x01: irq 11
cbb1 at pci2 dev 0 function 1 "TI PCI4520 CardBus" rev 0x01: irq 11
em0 at pci2 dev 1 function 0 "Intel PRO/1000MT (82540EP)" rev 0x03: irq 11,
address 00:0d:60:d0:dc:47
ipw0 at pci2 dev 2 function 0 "Intel PRO/Wireless 2100" rev 0x04: irq 11,
address 00:0c:f1:46:5e:29
cardslot0 at cbb0 slot 0 flags 0
cardbus0 at cardslot0: bus 3 device 0 cacheline 0x8, lattimer 0xb0
pcmcia0 at cardslot0
cardslot1 at cbb1 slot 1 flags 0
cardbus1 at cardslot1: bus 6 device 0 cacheline 0x8, lattimer 0xb0
pcmcia1 at cardslot1
ichpcib0 at pci0 dev 31 function 0 "Intel 82801DBM LPC" rev 0x01: 24-bit
timer at 3579545Hz
pciide0 at pci0 dev 31 function 1 "Intel 82801DBM IDE" rev 0x01: DMA,
channel 0 configured to compatibility, channel 1 configured to compatibility
wd0 at pciide0 channel 0 drive 0: <HTS548040M9AT00>
wd0: 16-sector PIO, LBA, 34682MB, 71029746 sectors
wd0(pciide0:0:0): using PIO mode 4, Ultra-DMA mode 5
atapiscsi0 at pciide0 channel 1 drive 0
scsibus0 at atapiscsi0: 2 targets
cd0 at scsibus0 targ 0 lun 0: <MATSHITA, UJDA755yDVD/CDRW, 1.71> ATAPI
5/cdrom removable
cd0(pciide0:1:0): using PIO mode 4, Ultra-DMA mode 2
ichiic0 at pci0 dev 31 function 3 "Intel 82801DB SMBus" rev 0x01: irq 11
iic0 at ichiic0
spdmem0 at iic0 addr 0x50: 512MB DDR SDRAM non-parity PC2700CL2.5
spdmem1 at iic0 addr 0x51: 256MB DDR SDRAM non-parity PC2100CL2.5
auich0 at pci0 dev 31 function 5 "Intel 82801DB AC97" rev 0x01: irq 11, ICH4
AC97
ac97: codec id 0x41445374 (Analog Devices AD1981B)
ac97: codec features headphone, 20 bit DAC, No 3D Stereo
audio0 at auich0
"Intel 82801DB Modem" rev 0x01 at pci0 dev 31 function 6 not configured
usb1 at uhci0: USB revision 1.0
uhub1 at usb1 "Intel UHCI root hub" rev 1.00/1.00 addr 1
usb2 at uhci1: USB revision 1.0
uhub2 at usb2 "Intel UHCI root hub" rev 1.00/1.00 addr 1
usb3 at uhci2: USB revision 1.0
uhub3 at usb3 "Intel UHCI root hub" rev 1.00/1.00 addr 1
isa0 at ichpcib0
isadma0 at isa0
pckbc0 at isa0 port 0x60/5
pckbd0 at pckbc0 (kbd slot)
pckbc0: using irq 1 for kbd slot
wskbd0 at pckbd0: console keyboard, using wsdisplay0
pms0 at pckbc0 (aux slot)
pckbc0: using irq 12 for aux slot
wsmouse0 at pms0 mux 0
pcppi0 at isa0 port 0x61
midi0 at pcppi0: <PC speaker>
spkr0 at pcppi0
lpt2 at isa0 port 0x3bc/4: polled
aps0 at isa0 port 0x1600/31
npx0 at isa0 port 0xf0/16: reported by CPUID; using exception 16
fdc0 at isa0 port 0x3f0/6 irq 6 drq 2
biomask effd netmask effd ttymask ffff
mtrr: Pentium Pro MTRR support
umass0 at uhub0 port 3 configuration 1 interface 0 "USB DISK 2.0" rev
2.00/10.29 addr 2
umass0: using SCSI over Bulk-Only
scsibus1 at umass0: 2 targets, initiator 0
sd0 at scsibus1 targ 1 lun 0: <USB, DISK 2.0, 1029> SCSI0 0/direct removable
sd0: 1944MB, 512 bytes/sec, 3981312 sec total
softraid0 at root
root on sd0a swap on sd0b dump on sd0b

Disk: wd0       geometry: 4697/240/63 [71029746 Sectors]
Offset: 0       Signature: 0xAA55
            Starting         Ending         LBA Info:
 #: id      C   H   S -      C   H   S [       start:        size ]
----------------------------------------------------------------------------
---
*0: 07      0   1   1 -   4696 239  63 [          63:    71018577 ] NTFS

 1: 00      0   0   0 -      0   0   0 [           0:           0 ] unused

 2: 00      0   0   0 -      0   0   0 [           0:           0 ] unused

 3: 00      0   0   0 -      0   0   0 [           0:           0 ] unused


Disk: sd0       geometry: 3949/16/63 [3981312 Sectors]
Offset: 0       Signature: 0xAA55
            Starting         Ending         LBA Info:
 #: id      C   H   S -      C   H   S [       start:        size ]
----------------------------------------------------------------------------
---
 0: 00      0   0   0 -      0   0   0 [           0:           0 ] unused

 1: 00      0   0   0 -      0   0   0 [           0:           0 ] unused

 2: 00      0   0   0 -      0   0   0 [           0:           0 ] unused

*3: A6      0   1   1 -   3936   8  63 [          63:     3967992 ] OpenBSD

# /dev/rsd0c:
type: SCSI
disk: SCSI disk
label: DISK 2.0        
flags:
bytes/sector: 512
sectors/track: 63
tracks/cylinder: 255
sectors/cylinder: 16065
cylinders: 247
total sectors: 3981312
rpm: 3600
interleave: 1
trackskew: 0
cylinderskew: 0
headswitch: 0           # microseconds
track-to-track seek: 0  # microseconds
drivedata: 0 

16 partitions:
#                size           offset  fstype [fsize bsize  cpg]
  a:          3800000               63  4.2BSD   2048 16384    1 # /
  b:           167992          3800063    swap                   
  c:          3981312                0  unused                   

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