I had a setup working with the WNR3500L and a USB hard drive drive formatted with ext3 and mounted through JFFS. I could access everything perfectly through the SAMBA share. The drive started out clean (no data).
I then tried copying my data to the disk via a USB connection from my linux box since the rates are faster.
After putting the USB drive back in it won't mount it. I tried a 30/30/30 reset but the drive still will not mount.
Does a drive have to be clean to set up NAS?
No the drive does not have to be clean. If you are using dd-wrt check the output of Services->USB->Disk Info
I am using DD-WRT, specifically your 15000 build. The problem is that the drive is not recognized and under Services > USB > Disk Info it simply states "Not Available".
It's very strange since it was working before I wrote data to the disk via USB connection. Should I re-flash the firmware?
It looks like a 30/30/30 reset may not fix this problem in all cases. As I stated above, I tried this several times to no avail.
It turned out I needed to flash my firmware again. It was able to mount the drive after that.

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