The problem is caused by Formatting the HDD in Vista before moving back to the system.
Simplest fix, hook it back to the Vista system and delete the partition from the drive in disk management. Once that is done, then put the drive with no partition in the XP system and boot to the XP CD, create a new partition and install XP
I would suggest using NLite to create a bootable cd using the Windows cd that you have configured just the way you want it.
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