Hey no problem CC_333

I saw that you were having a problem with your card and I figured I might be able to help. Hopefully this will help and we'll all benefit from the new knowledge about the firmware.
I just tried the DOS flasher to put ROMFILE.1S2 (the 5.1.3 version) contents onto an SST chip. I padded ROMFILE.1S2 with 0xFF bytes at the end so it is exactly 256 KB in size, as suggested earlier in this thread by jruschme. The verify did fail once, so the DOS flasher still isn't completely reliable...give it multiple chances if the first time doesn't work. I verified again and the second verify was successful. Anyway, it doesn't kernel panic, but it doesn't work either.
max1zzz: it looks like the kernel panic is specific to the new 5.3.1b1 version. Here are my results with OS X 10.4.11 on my B&W G3:
- SST chip, 5.3.1b1: kernel panic
- PMC chip, 5.3.1b1: success
- SST chip, contents of ROMFILE.1S2: successful boot. Apple System Profiler doesn't show the card under PCI, but IORegistryExplorer with the dev tools sees the card. Appears that the driver doesn't load.
In fact, with ROMFILE.1S2 flashed to my SST chip, the system.log file in the Console app shows the FirmTek driver 5.1.3 loading but it bails out. It doesn't have the message about looking at the chip ID, but I'd have to assume that's why it's bailing especially after what 5.3.1b1 does. Probably just doesn't kernel panic when it fails and instead fails silently. So I really, really think that the chip ID is being checked.
Edit: OH, the card extracts its driver kexts (two of them -- FT_ATA_Sil3112.kext and Sil3112DeviceNub.kext) into /System/Library/Caches/com.apple.romextensions. One purpose of FSCAPP is to clear those out after the firmware changes.
So ROMFILE.1S2 appears to have weird encoding because it contains a compressed version of these kexts that are expanded out to the actual computer. ROMFILE.1S2 should definitely be written directly to the flash chip, no special encodings. I'm sure of it now.