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SOLVED!

So I used EOSCard on a PC to prepare the card. Put latest nightly on it and BOOM. Works exactly as it should. I'm running ML 1.1.3 dated 03 Jan.

Hooray.

I worked out what was causing the problem:

Deleting the contents of the ML card (not formatting, just deleting) using finder on mac was making the card non-bootable for ML 1.1.3.

I have NO IDEA why that would happen.

It was made even more confusing due to that process working fine for 1.2.3 whenever I reverted back to it...

Again - no idea why it would remain bootable for 1.2.3 but not for 1.1.3 using the same process (deleting and replacing contents.... NOT formatting).

Walter thank you so much for your continued help.

Whats confusing is that I haven't formatted the card at any time. Just deleted contents using mac finder window.

I'm going to download EOSCard/Macboot and check the card/change the card.

Just to confirm:

I have Canon 1.1.3.
I have bootflag set (it MUST be).

Then ALL I need is a working bootable card with ML 1.1.3 nightly on it....

Some thoughts:

What is of note is that when I have to revert back to 1.2.3 and use the ML5D3123.FIR to set the bootflag it does give me a message saying that the bootflag is already set. So you are absolutely right about Canon firmware changes not affecting the bootflag (I didn't doubt you anyway).

So the bootflag IS set on the camera.

The camera boots straight into vanilla Canon.

If there is a bootable card but no autoexec.bin then the camera would hang on startup.....

I removed the contents of my ML card. It doesnt hang.

Which means the the ML card is (for some reason) no longer a bootable card.

This MUST be it. (if my thinking is correct?)

I'll work on it.

Thank you for your patience.

Steps:

Have 1.2.3 ML running fine.
ML Card has autoexec.bin, ML folder and ML5D3123.FIR on it. Nothing else.
Remove ML Card
Have second card with Canon 1.1.3 on it because I don't want to mess with the bootable-ness of my ML Card.
Insert Card 2 with Canon 1.1.3 on it.
Update (backdate) firmware to 1.1.3.
Remove Card 2.
On my mac I delete contents of ML Card and replace with 1.1.3 nightly contents.
ML Card has autoexec.bin and ML folder only.
Camera boots. Doesn't load anything from card. Just plain vanilla 1.1.3.

Install Canon's firmware 1.2.3. Use Nightly Build for 1.2.3 to set cam's bootflag and make the card bootable. Downgrade to Canon's firmware 1.1.3. Delete ML folder and Autoexec.bin from card and copy extracted "ML for 1.1.3" to card.
Done. You are running ML for 1.1.3

Gah!

I'm sorry but this bit just doesn't seem to work. When I Downgrade to Canon's firmware 1.1.3 it resets the bootflag on the camera. It boots nothing from the 1.1.3 card.....

Install Canon's firmware 1.2.3. Use Nightly Build for 1.2.3 to set cam's bootflag and make the card bootable. Downgrade to Canon's firmware 1.1.3. Delete ML folder and Autoexec.bin from card and copy extracted "ML for 1.1.3" to card.
Done. You are running ML for 1.1.3

Really clear! Thank you!

Hello

I know this has been asked before - however after extensive searching I just cant seem to find an answer - or I don't understand any answer that I've read.

The 1.2.3 Nightly build hasn't updated since August 2014 - however the 1.1.3 Build is updated as of January this year.

Are there any plans to create a more recent 1.2.3 build?

I've tried reverting to 1.1.3 and then using a 1.1.3. nightly but they don't contain any .fir so I can't use them.

Is my answer just to wait for a new 1.2.3 nightly?

Many thanks and all help appreciated.