I very well may not have this problem solved by then! haha.
Ok well I did actually get it to work from a GX745 to a C610 this afternoon... but that presents a problem of it's own.
I have been building on the latest model and, and modifying the PC to work on all older models. When we began buying dual core machines this introduced machines that would not longer work on the ACPI HAL.
My process has been to build on the GX745 with a Core 2 Duo, when complete change the HAL driver to "Advanced Computer and Power Interface (ACPI)" prior to syspreping.
In my Sysprep.inf I included the line " UpdateUPHAL = "ACPIAPIC_UP,%WINDIR%\Inf\Hal.inf" ", in order to change the HAL back to a Multiprocessor HAL when it was detected by SYSPREP. This was working on all of my Desktop PC's, but not on my laptops.
Deleting the " UpdateUPHAL = "ACPIAPIC_UP,%WINDIR%\Inf\Hal.inf" ", line in Sysprep corrected the issue on my single core laptops, but has now broke the image for my multi-core machines.
So I need to find a better way to reliably correct the HALs.
I am about to try another method from here, called "My Sysprep".
http://jimtsay.googlepages.com/mysysprep
It has two methods for changing the HAL. The first I am going to try uses CPUID to detect the processor type, and change the HAL accordingly. I tried this process a couple of days ago, but I had mistakenly left the " UpdateUPHAL = "ACPIAPIC_UP,%WINDIR%\Inf\Hal.inf" ", line in SYSPREP when I ran it, and it failed.
The other method is scripting specific HAL's for each PC model, which will take more work, but if it works correctly it will be worth it.
Anyone have any other suggestions?