politicorific: would you mind posting back here with details on exactly what you did with "smart boot manager" to get m0n0wall booting? I know it would be of interest to people who run into this problem in the future.
absolutely, although it's been a couple days so here's what I remember:
This is how I got my old laptop which could only use a cd-rom (which I didn't have), a floppy drive(which I did have), or a hard drive (which gave me the dreaded "read error")
Step one: Write the m0n0wall .img file of your preference to your media(flash/hd)
Step two: Get angry that your computer shows "read error"
Step three: Download smart boot manager - 3.7-1 from
http://sourceforge.net/projects/btmgr/You want and only need "sbminst.exe"
Step four: find an old PC with a floppy drive, use sbminst to install to a floppy.
Write protect the floppy just in case, smart boot manager asks if you want to save settings quite often
Step five: insert floppy into m0n0wall box, set the bios to boot from floppy
Once the PC has booted it will read the floppy drive giving a text menu of options. Smart boot manager does not detect SCSI drives, usb drives, but it may detect a cd rom. Since you've already written the image to the drive you want, just choose "primary drive" or "dev/xxx" under the partition list.
Voila, m0n0wall should boot. After testing this a couple times, remove the floppy and turn off the write protect and restart the pc, now you should be able to select the primary boot option(f8) and set a delay timer of 1-2 seconds(control-t). This way m0n0wall boots automatically without the 30 second timer. Place floppy back in drive, save settings, remove floppy, and move write protect tab back in place.
The programmers of Smart Boot Manager do not encourage using sbminst.exe on hard drives - I had to re-write my partition tables a dozen times since this will install smbinst to the boot sector and the old notebook I was using didn't like this. Try it out if you really want to pull out that floppy drive