Thanks for all the help. As always, much appreciated.

I finally found the solution here: http://new.lowendmac.com/sable/07/mac-drive-setup-patch.html

I was using drive setup 1.5 but not the patched version. Now I can format any of my drives and they are all seen boot and work like a champ.

It's always great when you track down the solution to an old problem.