Old-Polack
Yes, the bootloader.pm is not the real problem, this is just something that will happen when you have high partition count > 10. Just proved it to myself, and when I followed the konsole record I reconised this is not what I was after.
For my clarification:
1.. Do I understand that the USB stick works fine when the partition count is 10 or under ( 1TB drive turned off bringing the count within range?)
2.. The big drive is USB
I am off to my notes again 
When the seeking is done from a liveHDD on
/dev/sdb13 (the 1 TB drive) the
<whatever>.sqfs file is found and boots properly, so the partition limit of 10 does not apply.
I think the problem with that drive specifically is that it ws partitioned with two different versions of fdisk, and there is some conflict in how the partitions are seen at a low level. I'm planning to wipe the drive and repartition it with the newest version of fdisk only, to see if that fixes things.
For the sake of argument, I added another 2 TB drive, so now the 1 TB has become /dev/sda, and all of the drives, other than the newest 2 TB drive, have more than 10 partitions.
[root@fatman ~]# fdisk -lDisk /dev/sdb:
750.2 GB, 750156374016 bytes
255 heads, 63 sectors/track, 91201 cylinders, total 1465149168 sectors
Units = sectors of 1 * 512 = 512 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0x2db1883a
Device Boot Start End Blocks Id System
/dev/sdb1 63 208844 104391 83 Linux
/dev/sdb2 208845 12225464 6008310 82 Linux swap / Solaris
/dev/sdb3 12225465 72244304 30009420 83 Linux
/dev/sdb4 72244305 1465144064 696449880 5 Extended
/dev/sdb5 72244368 272253554 100004593+ 83 Linux
/dev/sdb6 272253618 670713749 199230066 83 Linux
/dev/sdb7 670713813 731278799 30282493+ 83 Linux
/dev/sdb8 731278863 811378889 40050013+ 83 Linux
/dev/sdb9 811378953 1045767239 117194143+ 83 Linux
/dev/sdb10 1045767303 1280155589 117194143+ 83 Linux
/dev/sdb11 1280155653 1465144064 92494206 83 Linux
Disk /dev/sdc:
2000.4 GB, 2000398934016 bytes
255 heads, 63 sectors/track, 243201 cylinders, total 3907029168 sectors
Units = sectors of 1 * 512 = 512 bytes
Sector size (logical/physical): 512 bytes / 4096 bytes
I/O size (minimum/optimal): 4096 bytes / 4096 bytes
Disk identifier: 0x18eee7ae
Device Boot Start End Blocks Id System
/dev/sdc1 2048 2099199 1048576 83 Linux
/dev/sdc2 2099200 18876415 8388608 82 Linux swap / Solaris
/dev/sdc3 18876416 81790975 31457280 83 Linux
/dev/sdc4 81790976 3907029167 1912619096 5 Extended
/dev/sdc5 81793024 176164863 47185920 83 Linux
/dev/sdc6 176166912 281024511 52428800 83 Linux
/dev/sdc7 281026560 385884159 52428800 83 Linux
/dev/sdc8 385886208 805316607 209715200 83 Linux
/dev/sdc9 805318656 857747455 26214400 83 Linux
/dev/sdc10 857749504 910178303 26214400 83 Linux
/dev/sdc11 910180352 962609151 26214400 83 Linux
/dev/sdc12 962611200 1172326399 104857600 83 Linux
/dev/sdc13 1172328448 1382043647 104857600 83 Linux
/dev/sdc14 1382045696 1803573247 210763776 83 Linux
Disk /dev/sdd:
2000.4 GB, 2000398934016 bytes
255 heads, 63 sectors/track, 243201 cylinders, total 3907029168 sectors
Units = sectors of 1 * 512 = 512 bytes
Sector size (logical/physical): 512 bytes / 4096 bytes
I/O size (minimum/optimal): 4096 bytes / 4096 bytes
Disk identifier: 0xbbcb054b
Device Boot Start End Blocks Id System
/dev/sdd1 2048 4196351 2097152 83 Linux
/dev/sdd2 4196352 2101348351 1048576000 83 Linux
Disk /dev/sda:
1000.2 GB, 1000204886016 bytes
255 heads, 63 sectors/track, 121601 cylinders, total 1953525168 sectors
Units = sectors of 1 * 512 = 512 bytes
Sector size (logical/physical): 512 bytes / 512 bytes
I/O size (minimum/optimal): 512 bytes / 512 bytes
Disk identifier: 0x0000d21c
Device Boot Start End Blocks Id System
/dev/sda1 63 626534 313236 83 Linux
/dev/sda2 626535 16820054 8096760 82 Linux swap / Solaris
/dev/sda3 16820055 114495254 48837600 83 Linux
/dev/sda4 114495255 1953520064 919512405 5 Extended
/dev/sda5 114495318 329332499 107418591 83 Linux
/dev/sda6 329332563 534434354 102550896 83 Linux
/dev/sda7 534434418 596943269 31254426 83 Linux
/dev/sda8 596943333 659452184 31254426 83 Linux
/dev/sda9 659452248 721961099 31254426 83 Linux
/dev/sda10 721961163 784470014 31254426 83 Linux
/dev/sda11 784470078 994198589 104864256 83 Linux
/dev/sda12 994198653 1623368249 314584798+ 83 Linux
/dev/sda13 1623368313 1685893229 31262458+ 83 Linux
/dev/sda14 1685893293 1749366044 31736376 83 Linux
/dev/sda15 1749366108 1816485614 33559753+ 83 Linux
/dev/sda16 1816487663 1889887982 36700160 83 Linux
/dev/sda17 1889892080 1953520064 31813992+ 83 Linux
Don't ask me why the drives read out of order, with /dev/sda listed last, as I haven't a clue.
