My fault - I installed a 'known-good' IDE hard drive and cable and results were the same.
I was in a rush to get this machine folding and forgot I had it's power supplied via UPS, which is where the relay clicking sound/failure was coming from. I have it up and running fine now and running F@H v6.23.
Sorry about not clarifying that in my original post but I actually forgot and I,ve never had an issue with this UPS so... now I'll need to find out what needs to be done with this UPS (Best technologies Patriot 280), if it's worth the repair cost
Thanks for the help guys!!!!