@socialtom, try the below (cut/paste from my blog).
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')A cold/hard boot (disconnect/reconnect power cord) can behave differently than a warm boot (executing the 'reboot' command via the console). Yes, very strange. I've experienced where if I do a cold boot, the default Pogoplug OS will boot up and not ALARM. However, if I execute a reboot command from within the default Pogoplug OS, ALARM will boot up properly. I've also experienced the opposite, where ALARM will boot up properly from a cold boot, but if I execute a 'reboot' command via the console, ALARM will not boot properly. This all depends on your USB flash/hard drive. Try the following, it may help and typically it shouldn't hurt. I'm using the below bootcmd for two of my Pogoplugs with Western Digital My Passport drives.
#E02 - Only. Fix boot issue with some USB drives
#credit -
viewtopic.php?f=18&t=1717&p=9527#p9527#print default bootcmd value
fw_printenv bootcmd
#default bootcmd
#[root@pogoplug ~]# fw_printenv bootcmd
#bootcmd=usb start; run force_rescue_bootcmd; run ubifs_bootcmd; #run usb_bootcmd; usb stop; run rescue_bootcmd; run pogo_bootcmd; #reset
#update bootcmd value to start, stop and start usb again
#all one line
fw_setenv bootcmd "usb start; usb stop; usb start; run force_rescue_bootcmd; run ubifs_bootcmd; run usb_bootcmd; usb stop; run rescue_bootcmd; run pogo_bootcmd; reset"
#confirm update
fw_printenv bootcmd