UPDATE
Dumped another 5 hours into it tonight, testing as many as 10 other chips on the board and noting their behavior. Xecuter2s worked fine and loaded Cromwell. Chameleons would either frag or the MS BIOS would load. I noticed the blue LED faintly flickering, so I knew it was getting SOME voltage. The Chameleon gets its 3.3V from pin 9. I was having trouble getting a voltage reading on it, so I checked continuity between the pin in 9 and the solder in 15 (also 3.3V) and got continuity with 0 ohms. So I knew the power was fine. Checked the ground on pin 2 to the screw hole used by the Xecuter line. 0 ohms. Reassembled the Xbox and booted it up, MS BIOS. Hard-grounded the d0 to the screw hole, then it fragged. Checked pin 2 again - NO CONTINUITY to the screw hole!!! Checked again. CONTINUITY. Checked again. NO CONTINUITY. Like I said, I've soldered it many, MANY times and I know my soldering is perfect in this case. I ran a bit of 30awg from the solder at the base of pin 2 to a nearby ground point (a small silver square). Reassembled with the customer's Chameleon, still frags! However, I tested it with all my other chips. They all booted Cromwell, Chameleon Cromwell, FlashBIOS, etc. JUST the customer's chip won't work now.
So it looks like grounding the d0 isn't enough to power the chip. The chip NEEDS to grounded on pin 2 or else it will not be able to function properly and the Xbox will receive a frag. For those reading this, hard-grounding the d0, which usually works as a diagnostic procedure, is not always sufficient with the Chameleon.
With respect to this scenario, the evident problem was a faulty ground on LPC 2 and a defective Chameleon. As noted, I repaired pin 2 by manually grounding it. Also, I had a few sample Chameleons that Xodus had sent me, so I've installed one at no charge to the customer, and the Xbox is now buttoned up and perfectly modded. The only difference is the jumper wire between pin 2 and the ground.
This post has been edited by Xeero: Aug 2 2003, 06:18 AM