OK
Hopefully I'm not annoying anyone with my updates.
Here is the latest:

I deleted the 5.2.6 install and installed 5.2.12, like so:

backup the config files etc.
delete all tapes by rewind, writing eof, rewind each one
do a: make uninstall of bacula
make sure that everything is deleted. I did this, and then deleted and
recreated the bacula db, so Everything is wiped
download the latest version and install, configure, used my previous config
files
see how bacula recognizes tapes

And after doing an : barcode label, I'm basically back where I was. Only 4
out of 8 tapes are recognized. At least it's behaving consistently broken.

*status slots
The defined Storage resources are:
     1: File
     2: HP Autoloader
Select Storage resource (1-2): 2
Connecting to Storage daemon HP Autoloader at pmappp01.tpmcomm.com:9103 ...
3306 Issuing autochanger "slots" command.
Device "HP-0" has 8 slots.
Connecting to Storage daemon HP Autoloader at pmappp01.tpmcomm.com:9103 ...
3306 Issuing autochanger "list" command.
 Slot |   Volume Name    |   Status  |     Media Type       |
Pool          |
------+------------------+-----------+----------------------+--------------------|
    1*|                  |         ? |                    ?
|                  ? |
    2*|                  |         ? |                    ?
|                  ? |
    3 |         TPMBU001 |    Append |                LTO-4 |
Default |
    4 |         TPMBU005 |    Append |                LTO-4 |
Default |
    5 |         TPMBU007 |    Append |                LTO-4 |
Default |
    6 |         TPMBU015 |    Append |                LTO-4 |
Default |
    7*|                  |         ? |                    ?
|                  ? |
    8*|                  |         ? |                    ?
|                  ? |

So at this point, I'm not sure what to think. When I do an: update slots
scan, it returns the correct slot and correct Volume name for all tapes in
all slots. I did this before doing a label barcodes, so it seems to be
reading the barcodes (this is after writing eof)

but when I do a label barcodes, it only labels 4 out of 8 tapes. It's like
it only sees 4 slots during this operation.

I'm going to see how backups run over the weekend, hopefully I'll get a
full backup.

I'm wondering if it's possible that a cabling issue could cause this, or
some incompatibility with the controller card. Or 4 tapes went bad at the
same time, but that seems extremely unlikely. I tried the btape test again,
everything passed, even when using one of the 'mystery tapes' so I don't
think it's the tape. When I check the mysql db, it says:
mysql> select concat(VolumeName,', ',Slot) from Media;
+------------------------------+
| concat(VolumeName,', ',Slot) |
+------------------------------+
| TPMBU001, 3                  |
| TPMBU005, 4                  |
| TPMBU007, 5                  |
| TPMBU015, 6                  |
+------------------------------+
4 rows in set (0.00 sec)


I'm sure people have had longer battles with bacula, but I'm getting
discouraged. I'm thinking about taking the 4 "good" tapes out, connecting
the tape drive to the old backup server, and trying backups using the same
"bad" tapes and slots. That would rule out tapes and slots. any suggestions
much appreciated, bacula is breaking me

At least it's Friday,
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