wildwilly,
There is clearly something wrong with the Drive D on your system.
Go to the maxtor web site and download their diagnostic software. This runs in DOS, so it is particularly appropriate in your case.
What you need to find out is if there is a DOS device driver installed (MAXBLAST or whatever) from your first setup of the drive. I do not believe the XP conversion of the drive to NTFS would touch this driver if already installed, but without it running DOS cannot see the drive if it was still FAT32, and certainly would be confused by the later conversion to NTFS.
The Maxblast utility used to allow the removal of the bootloader driver, I do not know if it still has this feature. I suggest calling Maxtor tech support to ask them about how to handle this problem without losing any data. It may not be possible.
On a related issue, you do not need two drives to slipstream SP1 into XP in any case. It can be done on one drive without problems, albeit it is slightly slower. Furthermore, all of the instructions you may want to carry out on the SP1 image for slipstreaming can be done from the Start, Run box and does not require going to a DOS session at all. Below is my 1 drive, no DOS slipstream of SP1:
1. In Explorer, Make a new Folder for C:\, and two subfolders:
XP
. XP_ROOT
. XP_SP1
2. In Explorer, Copy all of the XP CD into folder XP_ROOT
3. In Explorer, Copy your Service Pack #1 into C:\XP
4. In Explorer, rename the Service Pack to XP_SP1.exe
5. Start, Run:
C:\XP\XP_SP1.EXE -U -X:C:\XP\XP_SP1
6. Start, Run:
C:\XP\XP_SP1\UPDATE\UPDATE.EXE -S:C:\XP\XP_ROOT
7. Your slipstream is done. The Folder C:\XP\XP_ROOT contains the completed slipstream image. You do not need or want to include XP_SP1 in your final burn. I assume you know how to make the disk bootable, as I will not give instructions as to this.