@RufusA: on the black screen issue: does it only happen when booting or also sometimes when backlight is turning on and off?
To date I've only encountered it when booting, never after unlocking, but have only been using the device in earnest for a week.
For example this morning it took 6 attempts to boot before it successfully launched Rockbox (although this is unusual, normally 1 in 3 attempts fail).
Most failures are a black screen after the creative logo has flashed on the screen for the 2nd time. When showing the black screen, the power led is lit green, but the menu and power slider are unresponsive and the only option is the reset button.
The other failure is a white screen immediately after the loading firmware... executing message appears on the screen - again reset of player needed.
I will post a RC bootloader in this thread tonight. If you report that the lcd still has issues, I will downgrade the X-Fi to unstable.
I'll give this bootloader a try after posting. I'll also try and see if there is any pattern in the boot failures.
Thanks again for all your assistance.