"Have you tried uninstalling the TS controller & unplugging the serial cable that goes to it to see if you still get the same problem"
When the touchscreen cable is disconnected, windows will load perfect every time even with the drivers/software installed.
"Do you have the same problem with the CoPilot GPS receiver not being able to be plugged in when windows starts? "
I've had no problems with the copilot reciever and leave it plugged in all times.
Does the nic cause problems with the AC-DC PSU?
I think in your case the 5V rail may be overloaded. After you install the driver, the next boot will required the device to be queried/initialized and takes a little more power.
In your sig, I see you have an Athlon XP 1100, is that a typo? I can't find any specs on the 1100. If its a .18 micro chip, you are really pushing the 5V rail. The lowest clock rate chip draws 60W or 12A on the 5V rail. The Opus can provide 10A with a temporary peak of 13A and so is overloaded by the CPU alone, but you still need power for the hd, pci cards, usb, etc. If you have a .13 micro chip, its a little more forgiving. The 1700, uses a little under 50W or 10A and is within spec.
If you underclock the CPU, you may be able to save some power. Try underclocking to lowest fsb and multiplier and decrease the vcore if not automatic. Also, do a before and after of power usage. The PC health section in bios should show you the stats.
I checked my power stats in the bios with the AC-DC and OPUS PSUs.
______ AC-DC OPUS
12____ 11.55 __11.79
5vsb___ 4.94___ 4.89
Only the 5V rail is lower with the Opus, but it is still well within ATX spec. Nonetheless, I will test with the AC-DC when I get my hands on an inverter or access to a garage.
Do a similar comparison and see how your setup fairs. And see how much underclocking helps with voltages. You can also try using motherboard monitor and running a cpu intensive task to see how the voltages get affected with both the AC-DC and Opus. If the 5v falls to low, it may explain the reboots.