Is there a way to manually install pfSense, or at least install /boot in a separate partition? I've been trying to get a 120GB SATA HDD to work for a couple days, but it sticks. I then threw in an 80GB. Same thing. Then I found an old 40GB SATA and tried it. Worked perfectly.
I came to the assumption that the board I'm using, an Intel SE7520BD2, does not like a boot SATA disk >64GB. Strange, I know. So my idea was to create a 512MB /boot slice in it's own partition at the beginning of the disk. Once it loads the kernel, it would boot from the main partition.
Choose the custom install option and define a / partition that's smaller than 64 GB (probably put the rest on /usr/).