Thanks for the speed tips! I checked with that utility and it's running at UDMA4, but that wasn't the issue. I forgot that when copying from my music server over my gige network to a USB drive, transfers go slow for some reason... Copying from a local drive, I timed about 70 seconds for a 1400MB file, or 20MB/sec.
I took some more pics and closed it up and have copied about 160GB of music to it now, mostly flacs and preliminary tests are good. No problems listening to the last folders copied over. I'll take it to work the rest of this week and see how it goes.
Here's chkdsk output (win XP):
The type of the file system is FAT32.
Volume AEGIS MINI created 9/15/2009 3:46 PM
Volume Serial Number is 239D-42BC
File and folder verification is complete.
Windows has checked the file system and found no problems.
234,371,232 KB total disk space.
23,840 KB in 743 folders.
166,434,304 KB in 9,114 files.
67,913,056 KB are available.
32,768 bytes in each allocation unit.
7,324,101 total allocation units on disk.
2,122,283 allocation units available on disk.