I also have the same problem.
Mounting encryped external media don't work correctly for me since Feisty. In 
Feisty it was horrible. Sometimes it worked correctly, bust most of the time it 
didn't. See also this report: 
https://bugs.launchpad.net/ubuntu/+source/hal/+bug/88213
Now I'm glad that things have changed in Gutsy. Until now, every first insert 
of an encrypted USB-harddisk/stick works fine. In my case that is a huge 
improvement in comparison with the situation in Feisty. But if I eject the 
encryped media and insert it again, nothing happens. No promt for the password, 
nothing you can notice at the desktop.

Peter Wainwright wrote: "So, in this case it thinks it already has
constructed the clear text volume? Perhaps HAL has some stale
information in its cache from the previous mount?"

I'm the same opinion. If I start gnome-mount manually, it tells me
something similar:

[EMAIL PROTECTED]:~$ gnome-mount -vbd /dev/sdb1
gnome-mount 0.6

** (gnome-mount:6526): WARNING **: Crypto volume 
'/org/freedesktop/Hal/devices/volume_uuid_e6dff7d4_8180_44e4_a245_313a7c629f87' 
is already setup with clear volume 
'/org/freedesktop/Hal/devices/volume_uuid_ed993252_5606_4872_98a3_43bea8e20a7a'
[EMAIL PROTECTED]:~$


There are two strange things I have noticed:
1. In 3-5% everything is ok! So sometimes (but realy only sometimes) it isn't a 
problem to eject and insert again. Until now I don't know the reason for.
2. I think it is strange that the output of gnome-mount (like I wrote above) 
contains two different uuids. (maybe that is ok, I don't know.)

-- 
mounting Luks encrypted USB-HDD does not work reliably
https://bugs.launchpad.net/bugs/148003
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Bugs, which is the bug contact for Ubuntu.

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