@maxg:
I'm interested to hear more about your mods for C1K... In particullar, where you are getting +5v for WiFI module (assuming it's powered from usb bus)? Or if it's +3.3V, still where you can draw appox. 350-450mA? By the way, which WiFi module do you use?
Were you able to find/trace lines for BT UART or second USB host port inside the C1K?
Also, it would be nice to see some pictures to support "it IS quite simple" allegation...
@duhbert:
On stock C1K with Sharp rom, the nand flash chip has the following partitions:
0x00000000-0x00700000 : "smf"
0x00700000-0x04100000 : "root"
0x04100000-0x08000000 : "home"
So, it looks like you trashed your root fs by formating it as ext2 fs. To get it back, you'll need to restore from a nand image. But unless you did something else too, updater should not be affected, since it lives in the first nand partition. So, it doesn't really explain why you can't boot it into updater's mode.
Did you try to hook up a serial cable to your C1K's I/O port and see if it spits any messages?
-albertr