If you only want to boot directly to HDL, without the OSD-Hack and FMCB 1.6-Features, I suggest you to use FMCB 1.5 with 75KB-DVDELF.bin.
This can do what you want, it don't waste so much space than FMCB 1.1, it is a bit more flexible (you can also hold a button, to start an app), it is configure-able, the problem shouldn't occur anymore and you have embedded USB-Drivers, to load your apps from stick.
If you don't delete the osdmain.elf, FMCB 1.5 is very "ROCK SOLID".
It also has the RESCUE.ELF for the first time and since FMCB 1.5 still have embedded USB-Drivers, it is nearly impossible to make it useless.
PS2 V7/DMS3 V2 (FW:2.4b7); Seagate Baracuda 200GB
PS2 V7/CC1.0 (FW:34 hacked v2 BM:2.1.6); Maxtor DiamondMAX9 PLUS 160GB
PS2 SCPH-30004R; NoMod+NoLaser
3xSony MC 8MB
MAX/Datel 16MB with Boot-CD
Custom FMCB 1.8b+ Beta-Build, my AIO 0.5, Sony&xRhino-Linux