I am thinking this may be hardware issue, b/c I am seeing something else very strange. I thought that maybe knoppix was having a hard time with the size of the parition, so blew that one away, and created a small 5Gb partition as part of the raid array. I was able to successfully chroot. So I did my customiziations, and created a new knoppix iso. I then ran an md5sum on the iso file. Funny thing I noticed, is that each time I run it on the .iso file, it changes!!! So I thought maybe I had bad CD-ROM or faulty ram. But I ran memtest86 and swapped out CD-ROMs, and I still see the same thing. I even went back to an older version of knoppix and I still see the problem.

So the only thing left to question is the raid array. Has anyone else seen this type issue where md5sum keeps changing?