Sent my AV500 in for a minor repair with the navigation buttons.  You may recall my previous post about the flaky right nav button.  Received the AV500 back after about a total of about 2 1/2 week turnaround time.  Not all that impressive, but it did come back fixed.  However, after only 2 weeks of use the hard drive failed.  I was finishing a business trip when I powered it up at the airport.  Needless to say I was a bit pissed.    
Called Archo Tech Support right away and got another RMA number.  They sent me a shipping lable since it was recently repaired.  UPS Ground though, I had expected they would overnight it.
We will see how quickly they can expedite the repairs.  If they indeed expedite as they say they would.
My questions are - Anyone have multiple failures with their units?
Anyone sucessfully create a backup HD for their units?  I see several have discussed creating a back-up drive, but any luck?  I was thinking of buying a spare 100 gb laptop hard drive and using Norton Ghost to create an image.
Tim