I found that booting from 1.6Z floppies fails every time while 1.6.1 
succeeded *almost* every time with my system.
I've seen a timeout error prevent boot also,  I retried with different 
floppies (the same 1.6.1 floppy images on different physical media) and it 
worked finally. So try all the different 1.6* images on the best floppy 
disks you can find.
I used RaWrite32 on Win2k.

I also abandoned my attempt at making a floppy image on MSDOS disks.

Sorry I can't give you a plan that is certain to work, hope this helps.

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