Format the card and image it, try to boot, if it won't boot take a few asic cards out so you can read teh BBB and eject the sd card while the unit is on, then put it back in, you'll see the ethernet lights cycle, I've had that make mine turn on before.
In other news, I did have a bad BBB that wouldn't write to the SD card. I replaced it with a factory BBB, that's what my machine is using now
Ahhhh, now THAT was some f'ing good advice! thanks mate - you're the best. followed these steps and got each one working with 8 boards. Sweated like a blackjack player holding 17 for a while, wondering if i should stick with what works or risk it and try adding the other two boards.
I chose to try something new - i ejected the SD card while it was running. Left it like this for about 5 minutes. it kept mining! i then powered it off, added the two boards, popped the card back in and turned it on. magically, it booted it up just fine!
So, until i figure out something better, this is my step-by-step to deal with the corrupt SD card problem:
shut off
remove 2 asic boards and sd card
reimage sd card via laptop
boot up with 2 cards missing, pop card in and out until it boots (you can tell when the blue lights on the BBB card near the ethernet card light up)
when it's running, pop out SD card, power off, then add 2 boards, pop card back in and hope for the best.