Thanks for the suggestions! I tried them all but none worked.
I swapped USB flash keys, same problem, so that tells me the keys are prepared
properly (HP format tool, -ma, fat32, etc)
Summary:
#1 ASUS A7N8X-E Deluxe (nForce2), 1GB -- both 4.2.4 and 4.3b6 work fine.
#2 ASUS P5N32-SLI Deluxe (nForce590), 2GB -- 4.2.4 works fine, 4.3b6 hang loading bzroot
Counting dots, it doesn't look like syslinux competes the uncompress of bzroot and it
hangs in the same spot everytime. What I'm unable to determine is if the hang is in
syslinux or after jumping into the early kernel init. I wish I had access to an x86 hardware
debugger.