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Why is installation failing with a particular hard drive (older - 2010 - Western Digital 160gb blue)?

I've built a 2 UTMs now (1 for myself, one for family) and trying to do same for another family member - using pretty much the same components.  But this round, I've been having trouble.  Installation actually succeeds, but when I reboot, I get nothing - can't find bootable media.  I thought it was BIOS issues and mucked around a bunch with that, then tried a new DVD...nothing fixed it.  I yanked the disk, and the partitions look okay to my untrained eye.  I struggled with setting BIOS to legacy vs uefi, tried 32bit installation, etc nothing seemed to work.  I finally said "screw it" and went and grabbed a very worn barracuda and subbed that for the WD Blue and...NO PROBLEMS!  I don't want to use the barracuda though - I know its on its last legs (lotsa clicking).  I used the same cables...same SATA port...  I literally unplugged power and data, removed Blue, put in Barracuda - worked.  What's going on?

Processor is an Intel 4170

Motherboard is Asrock server board, with two intel LAN ports

Memory is 8gigs of DDR3

and I added a 4 port intel NIC off the compatibility list that the installer sees just fine.  The boot stuff on the NIC is annoying (because it delays booting to other sources), but that doesn't stop the Barracuda from working

Anyone have any troubleshooting ideas?  Is it possible the Sophos installer is getting mucked up trying to repartition the Blue drive for some reason?  I already tried using Gparted Live on it to look for problems, and do a repartition before going through installation again - didn't seem to help.  Any advice appreciated!

`Confused



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