It is possible that the problem lies with cryptsetup.  Even when
manually performing the steps

cryptsetup luksOpen /dev/sdb1 luks
cryptsetup luksClose luks

I still end up with some "leaked" devices.  These can cause the "already
setup" error.  For example I have

/org/freedesktop/Hal/devices/volume_part_1_size_64000

[EMAIL PROTECTED] cryptsetup-1.0.5]$ lshal -l -u 
/org/freedesktop/Hal/devices/volume_part_1_size_64000
udi = '/org/freedesktop/Hal/devices/volume_part_1_size_64000'
  block.device = '/dev/mapper/temporary-cryptsetup-24059'  (string)
  block.is_volume = true  (bool)
  block.major = 254  (0xfe)  (int)
  block.minor = 0  (0x0)  (int)
  block.storage_device = 
'/org/freedesktop/Hal/devices/storage_serial_disgo_disgo_021D93010900B1E0_0_0'  
(string)
  info.capabilities = {'volume', 'block'} (string list)
  info.category = 'volume'  (string)
  info.parent = 
'/org/freedesktop/Hal/devices/storage_serial_disgo_disgo_021D93010900B1E0_0_0'  
(string)
  info.product = 'Volume'  (string)
  info.udi = '/org/freedesktop/Hal/devices/volume_part_1_size_64000'  (string)
  linux.hotplug_type = 3  (0x3)  (int)
  linux.sysfs_path = '/sys/block/dm-0'  (string)
  storage.model = ''  (string)
  volume.block_size = 512  (0x200)  (int)
  volume.crypto_luks.clear.backing_volume = 
'/org/freedesktop/Hal/devices/volume_uuid_c52cc2c6_8fbd_41b3_a99f_f4a7d3132c9c' 
 (string)
  volume.fstype = ''  (string)
  volume.fsusage = ''  (string)
  volume.fsversion = ''  (string)
  volume.is_disc = false  (bool)
  volume.is_mounted = false  (bool)
  volume.is_mounted_read_only = false  (bool)
  volume.is_partition = false  (bool)
  volume.label = ''  (string)
  volume.linux.is_device_mapper = true  (bool)
  volume.mount_point = ''  (string)
  volume.num_blocks = 125  (0x7d)  (int)
  volume.size = 64000  (0xfa00)  (uint64)
  volume.uuid = ''  (string)

This temporary-cryptsetup-XXXXX device is created by cryptsetup
luksOpen, but it was supposed to be freed by clear_mapping().

By the way, my Fedora 7 box does this perfectly.  You might want to see
what is different with that.

-- 
mounting Luks encrypted USB-HDD does not work reliably
https://bugs.launchpad.net/bugs/148003
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