Ok. So I decided to test the drive a bit more before sending it back. Newegg gave me 7 days for the RMA.
I was planning to reformat the drive and just send it back, but when I went into my X3 live setup to do the format I decided to change the LBA option.
Now don't get me wrong here, I have changed this option several times while doing this whole SATA HD upgrade. And normally I would leave it on the option for an F and G drive.
Anyway, I just decided to try and change it to F and G drive again this time before I did the reformat. Well, what do you know, the damn thing decides to work now. Unfortunately not 100% though.
BUT, I did leave it on for over 8 hours copying (by FTP through PC) about 300 gigs of stuff over from my other HD which was in a borrowed Xbox.
It went through all of this with no problem. I left it on while I slept and when I woke up it was locked up with the HD LED on solid. Damn.
I've been randomly booting, rebooting, shutting down, playing games and leaving it running for the last couple days. It seems like it's ok now. But who the hell knows? I hate this! Now I'm considering building another Xbox just so I have a proper backup of it. Another $150 or so. Yeah I can afford that. (Yeah right).
It would be nice for my car though! LCD, new head unit with Aux input, maybe a new sub and amp. I think I need another job.
Maybe none of this is even worth the trouble! But I feel so commited now!
And yeah, I looked over the SATA adapter I got off of Ebay and the soldering looked pretty bad. I cleaned it up a bit, but doesn't seem to make a difference. Didn't notice any solder on the chip though. Maybe I need a stronger magnifying glass.
BTW, thanks to all those offering suggestions! And may I suggest, if you have this working well with NO problems maybe you could share some details about your setup?