Thanks for the comments and suggestions, it is comforting to have someone to bounce ideas off of.
I assume the source image is correct, since it passes an image check on the server. (When I use the ghost client on the server and access a local image). Your
comments seem to focus on image creation (which is what I was thinking earlier). But if the image check is a valid experiment, we must move to the restoration process in our thinking. I tried 3 switches, and various cable drops during the restore and still get errors. When multicasting to a pair of clients, both hit a CRC error at the same time (suggesting that the error was either in the received data, or the CRC calculation of the receiver). Since an image check on the server did not hit a CRC error, we have a limited number of candidates: ghostcast server calculated a bad CRC, server NIC, cable from server to switch, switch server is connected to.
Please note that I have attempted restores to multiple machines, so the liklihood that each has a hardware fault is remote. These are new machines, and I have ran a battery of diagnostics on each of them before moving them into the lab for imaging. For example, memtest 4.1 was ran against each of these machines for around 1 week, something like 200 passes were ran (they have 12G so it takes a while). Prime95 was ran for 3-4 days straight, except for one machine that had an error (we were not able to reproduce even after another 2 weeks of prime95). I'll run chkdsk on the machines anyways, although I don't think it is a particularly strong test. Drive manufacturers typically have far better tools available.
I strongly disagree with the idea that a bootable image which had CRC errors is correct (or suitable for production)! If a particular DLL is damaged, the machine may be bootable and work fine until that particular DLL is used. I need confidence that there are no unpleasant surprises in store for users, this means all files need to be exactly as they were when the image was taken.
BTW, for the benefit of anyone else reading this thread having similar problems: the answer to the question at the end of the original post was to run the ghost client on the server. A "check" option appears under local operations, navigate to where the images are stored and you can perform some level of validation of an image.
This is needed functionality, and I wish it was easier to find (perhaps add it to the ghost console?) At present, the only way you can know of the option is to browse the ghost install directory with Explorer and run "ghost32.exe" or "ghost64.exe". These are not added to the program group by default.