What you describe sounds like normal behavior if you unhide but don't unlock the extended rom before making changes to it. I've done that by accident before - made all sorts of changes that appear to work at first but then don't survive a soft reset. The extended rom unlocker is included in the current kitchen - you need to run it after finishing your flashing/hard-reset process. (You only have to do this once, then it's easy to forget later.)
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XV6700 w/ Custom Apache WM6 Kitchen CE OS 5.2.1908 (Build 18508.0.7.0) - from Helmi_c and the guys at PPCGeeks.com
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