I think you hit on the real culprit and ignored it, it seems that even modern
BIOS implementations, at least some of them, do not want to cross a cylinder
boundary doing boot. Or maybe that's dumb MBR code, which at least has the
excuse of being size limited.
I did try using 48 sector geometry on a virtual drive, and it seems as though
both Linux and XP will install. Then I tried on a USB stick and the BIOS in
several old Asus laptops will boot that.
I cautiously suggest that since nothing past boot used chs, and using 48 spt
seems to work and gives correct alignment, perhaps there is value in custom
geometry.
--
Bill Davidsen <davidsen@tmr.com>
"We have more to fear from the bungling of the incompetent than from
the machinations of the wicked." - from Slashdot
--