OK, me again, about 15 minutes later only! Well, here's the scoop:

16.74GB FAT32 partition, with the disklabel and boot sector backup
issues that everyone hates. I had all but 3 or 4 MB of that partition
filled. So, I just moved off approximately 1.91GB, tried to re-disklabel
it (btw, this is all being done via gparted in SystemRescueCD). So.
Tried to re-disklabel it. Nope. Sorry, Charlie. So, told gparted to
check and fix the partition (which as mentioned in last post, I had done
before, but did not have enough free space for fsck to grow partition,
etc.). This time, gparted whipped through the job in just 5 or 10
minutes at most, reporting all is well. Still got that butt-ugly
disklabel staring at me. So, here goes nothing....

I tell gparted to bitchslap that disklabel outta there - as in I told it
to apply a BLANK disklabel. Nice. Just like a hunting dog it tore into
the bushes and came back out with the prize - the disk label now can be
changed, evidently, at least to a blank! So, show me more, baby. Re-
label it SDB6-FAT32. Thank you. Copy my data back (yes, I know, I said I
was gonna re-partition, but don't we all just want to know if I've got a
reliable fix here? I sure do...). So, FAT-32, stuffed to the gills
again. Shut down, rebuntu my Ubunto and voila! No more mis-matched
backup booty sectors no more, no more no more! All is as good and well
as a FAT-32 partition can be.

Screw it. Gonna play some OpenArena tonight. I'll migrate the data,
paths, scripts and such another day (SURE, I will, LOL!)...

Hope this fun tale helps someone. I'm pretty sure I dealt with this
issue at least a handful of times, across several distros, across a few
years,. Hell, this partition is back from 1997 or so, Interstate '76
data and such on it, LOL! Someday I'll tell the tale of how I recovered
a majorly baked drive back in the mid-90s, and kept using it, even with
essentially a "GRAND CANYON:" of crappy sectors (far more than any
badblocks table could hold) right in the middle of it - that was my
primary partition back then, in those days, man! I couldn't bear to not
have it (that and I'm too poor/cheap to buy disk space - hell hardware -
someone always gives me their old hand-me-downs.....

GOOD LUCK AND GOOD NIGHTT!

   -- Ax-L

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More info about "filesystem check fails on boot, but filesystem isn't bad"
https://bugs.launchpad.net/bugs/494843
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