I had a similar problem here, writing an image for the net4501 on a CF card. My configuration: Intel iMac Dual Core, OS X 10.5, hama Cardreader on USB 2.0, Silicon System CF Card 1 GB (too much for m0nowall, I know ;-)
Thanks to your report, I tried to write it on other operating systems. Unfortunately I did not have any other physical box available, so I tried with virtualized PCs. All of them in VMware Fusion 1.1.1. My first try Windows XP and physdiskwrite.exe failed. But I succeeded with a virtualized Ubuntu Server 6.01:
To prepare the following steps, insert the CF in the reader and connect it using the status bar of VMware Fusion.
First gunzip the file ($ gunzip -d net45xx ....)
Second type this command and make sure that you use the right disk (sdb may be different on your system!!):
dd if=net45xx-1.233.img of =/dev/sdb bs=16k
Hope this helps, Ingo.
P.S. Seems as if
you can have this much more easy - after rechecking my previous steps, I realized that if you use the right arguments and parameters you can do it also with dd from OS X (so without VMware fusion). The key is this line:
$ dd if=net45xx-1.233.img of=/dev/disk2 bs=16k
And that yo have to check, if the imagefile is still compressed or not (OS X may decompress it on the fly during download). This can be checked using the command "file". Following the output of an already decompressed imagefile.
$ file net45xx-1.233.img
net45xx-1.233.img: Unix Fast File system (little-endian), last mounted on /m0n0wall/mnt, last written at Wed Jan 23 23:28:47 2008, clean flag 1, number of blocks 7168, number of data blocks 6911, number of cylinder groups 1, block size 8192, fragment size 1024, minimum percentage of free blocks 0, rotational delay 0ms, disk rotational speed 60rps, SPACE optimization
Se also:
http://lanti.wordpress.com/2008/05/23/installation-m0n0wall-auf-soekris-mittels-imac-os-x-105/ (German)