Yes thanks Edward, it's flashed to latest.
So far looks like a case of 64bit being touchy.
Under 32bit it works with 8 drives in raid 0 and serving files. Only issue I've had is copying some files over from the current server, it kept saying things like invalid filenames and other errors, try again worked every time though, I'm thinking the network cable is just loose a bit and going through many power cables since the box is in the middle of the room at the moment.
Under 32bit the controller installs with the same driver package but separate files for 32 and 64 bit versions.
I'd try the other pci cards that had problems see if they're fine now too but for now it works so only thing I have left is mirroring the temp boot drive onto the 80gb. I used my old laptop drive to test 32bit, didn't want to wipe 64bit for nothing if it didn't work, especially after spending hours updating it.
Once it's mirrored and working, I'll unhook the 80gb and use the now redundant laptop drive to test the other pci cards without nuking the good install.
My best guess is that for whatever reason 64bit's larger address space in this case proves a problem rather than a solution, like there's too much to manage for interrupts, memory, hard drive addresses, etc.
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