Try (hd0,0): FAT32: disk error
........
Cannot find grldr
Even though it boots to grldr, as before trying to copy files to the 16GB CF in XP results in Windows totally locking up, mouse and all (this is on the VL400, on my Gigabyte system I've been able to copy files to it no problem, using Windows 7 anyway).
There is something wrong with the VL400 motherboard. Even Windows cannot operate on it smoothly in protected mode. Consider to upgrade the BIOS.
As for G4D and geometry, booting NTLDR from the CF, which loads boot.ini and selecting G4D from there, which loads grldr (0.4.4) and menu.lst from the HDD (as it can't see them on the CF), "geometry (hd0)" gives
drive 0x80 (LBA): C/H/S=1024/16/63 Sector Count/Size =1032192/512
I then updated the grldr on the HDD to 0.4.5c (17-01-2012) and after booting directly from the HDD, "geometry (hd1)" returns
drive 0x81(LBA): C/H/S=1943/64/63 Sector Count/Size=7834176/512
Both showed (LBA). So there should be no problem for most of the boot loaders. Especially WEE should run without any problem.
EDIT: Since it "cannot find GRLDR" or "cannot find menu.lst", it might have its limit for accessing large sector numbers. So you may try to work around it by fdisking a small partition located near the very beginning of the CF card, and only access this small partition on the boot-loader stage.
EDIT 2: You can find out the limit by hand:
cat --hex (hd0)8000000+1
cat --hex (hd0)4000000+1
cat --hex (hd0)2000000+1
cat --hex (hd0)1000000+1
cat --hex (hd0)500000+1
cat --hex (hd0)200000+1
cat --hex (hd0)100000+1
cat --hex (hd0)50000+1
cat --hex (hd0)20000+1
cat --hex (hd0)10000+1
cat --hex (hd0)5000+1
cat --hex (hd0)2000+1
cat --hex (hd0)1000+1
cat --hex (hd0)500+1
cat --hex (hd0)200+1
cat --hex (hd0)100+1
cat --hex (hd0)50+1
cat --hex (hd0)20+1
cat --hex (hd0)10+1
In this way you can find out the maximum of N such that the "cat --hex (hd0)N+1" command succeeds. And this N shows the capability(i.e., the limit) of your BIOS.
Warning! Use the latest build of 0.4.5c for testing. Earlier versions cannot be reliably used for this testing.