dasnas:
Ok, the overlay was wiped out by KillDisk, but the BIOS still only sees 31GB (because it's an old BIOS). Have you now tried to turn OFF HDD detection and tried NL again ? Look in the
SysLog to see if it finds the drive and reports the correct size. (If you have trouble interpreting the SysLog, post back the entire thing.)
If NL still does not correctly see the drive ... a few more suggestions.
Put the drive on a modern Motherboard/BIOS and verify it sees 80GB. If it does not, use KillDsk again. Then put the drive back in the AMD-K6 system, but make sure to have drive detection OFF before it boots. Also, does the AMD-K6 BIOS have an option to reset system configuration data ? Try that, and/or remove the CMOS battery for a few minutes (and no power connected).
When you say "other type of I/O card" ... was the 80GB connected during all these trials to the Aopen MB's on-board IDE channel or a PCI card ?

Georg