yeh that works with the network all do just r3966 doesn't

Now you have got that working, I recommend that you either stay with 4824 (with the old (=original) user interface) or update to firmware 7317 (with the new user interface (developed for the HD2 and Mini2 models)). In my opinion 7317 is better than the other GUI 2 firmware releases (5540 and 3966).
Your choice will depend on your taste and requirements. 4824 is less sophisticated but more reliable than 7317. To assess the differences please check the Mini user manual, which covers the 4824 firmware options and the Mini2 manual, which covers the features of the GUI 2 firmware.

but the thing is i don't like the older firmwares they look very basic and outdated and the whole reason i brought the hd mini is for the new gui2 and the new shortcuts feature and there only in the newer firmwares like 7317 but they have problems for me

If you got 4824 working, basically 7317 should also work. Are you sure you have the correct firmware, downloaded from here? The firmware releases for the other models have the same serial number, which is confusing.

Your problems may be caused by the fact that a previous owner may have had a non AC Ryan firmware installed and thereby damaged the boot loader. Unfortunately, this cannot be recovered.

yep i have been using that exact version

All I can say is that I can install any firmware (backward and forward) without problems. I do this regularly to check problems put forward on the forum.

Make sure that 4824 is working correctly and then try a MENU installation of 7317. There is no need to install the intermediate firmware releases.

This should work, unless your unit was damaged by a previous owner. Buying second hand involves a risk, unfortunately.

just to clarify i'm on 7317 atm and my only problem is the fact it fails to boot first time as it shows the error in the topic title and the 'fix' is to just unplug the device and boot it up again as it ALWAYS boots second time

That is not normal behaviour, because the Mini should boot from stand by without the necessity of a full power down.

Did you install 3582 twice? That may restore the bootloader.If that does not help, I am afraid your unit is defective.

yep i tried it twice and still the same

Since you write that you installed several firmware releases several times with different USB sticks, I assume that you also tried both USB ports for the firmware updates..

Reading the whole topic again my conclusion is that your Mini has a hardware defect. Why not try the RMA option given in one of the previous posts. I assume that the serial number of your unit indicates the date of manufacture. A 73200P+ model (see the sticker) cannot be more than two years old, because these were introduced in July 2010.