I'm not sure if anyone has ever tried copying one of your dumped ROMs and putting it into a Turbo 040.
I have, except....
I dumped the ROMs on my chip programmer. Then I programmed more ROMs of the 4.1 ilk (was replacing 68LC040 with full 68040), installed those and they worked fine. I also took the dump, which I had used to program additional chips, and uploaded it to my webspace (really ftp space, but never mind).
So, if there is corruption, it happened somewhere in the getting the file to the internet phase, not in the pulling the file off the chip phase.
Daystar might have done something as simple as scrambling the data pins when they programmed/read the ROM. If, e.g., you reversed the order of the data pins, everywhere you expect to see a 1, you'd see an 8. 0 would still be 0 and F would still be F, 9 would still be 9 and 6 would still be 6.
Anyway, might be interesting to look and see if a straight substitution code would unscramble it. Of course, if they scrambled the address lines as well, that would get messy.
I don't think it can actually be encrypted by mathematical algorithm. The reason is that either the Mac or the Turbo040 must be able to read the unencrypted contents. If the content is encrypted, where is a processor going to get the instructions for decrypting it? I suppose there could be some hardware logic (decryption PAL?) on the board, but that would add cost to the product. Scrambling the address and data lines doesn't add any hardware cost, and only requires them to (probablly) have some kind of adapter in between the chip and programmer at the factory.
Say, anyone remember if the Turbo040 was firmware updateable in the field?
I kind of think it was through the Control Panel, but I may be thinking of the Turbo601. I have this memory that one could do some special key combination to the Control Panel and it would offer to update the firmware on the Turbo040. I can't remember if there was a separate file, or if each update was embedded in the latest version of the CP.
I'm working from more than 20 year-opld memories here, so forgive me if I'm completely wrong.
Point being, it would interesting to see what any user uploadable update looks like.
I have some of the GAL based Turbo040s. One of these days I'm going to have tear one apart (delicately disassemble) and start tracing out things. The rate things are going, you guys will have it done before I can get the box out of the attic.