I will try to answer as many of these as I can. But some of this is beyond my knowledge as to how to get the information you are looking for. But if you tell me where to look I will get it.
1. On my current working install using BETA 2 there is no data in this file though it does exist.
2. According to the bootup on BETA 2 it is loading: em0
3. By machine model what are you referencing? This is a DIY PC my motherboard model is: Intel DH55TC
4. I have looked up information on my motherboard and it doesn't appear to support ipmi.
I looked through fresh checkouts of the branches, and the only change that I could possibly see it being is...
+# Debugging for use in -current
+options KDB # Enable kernel debugger support.
+options DDB # Support DDB.
+
What this could do is slow things down by accident, making a race condition that existed before more apparent.
First off, I would try updating your firmware to see whether or not the issue goes away after doing that. If all else fails, let's walk through the following debug decision tree:
When the machine first boots up and you look at the FreeNAS/FreeBSD bootloader (the screen where it says "Welcome to FreeNAS!"), could you hit 6 and...
Procedure 1:
1. Enter in `set hw.em.enable_msix=0'
2. Enter in `boot'.
This will disable MSI-X (it's a more advanced mechanism for receiving PCI interrupts) support for your em chipset.
Procedure 2:
1. Enter in `boot -v'.
This will spew out more messages on the console and might serialize things enough that your boot will succeed. I don't advise sticking with this option because it will fill up /var faster.
Procedure 3:
1. Enter in `set debug.debugger_on_panic=0'
2. Enter in `boot'.
This will disable the kernel debugger at boot.
Procedure 4:
1. Enter in `set hw.pci.enable_msi=0'
2. Enter in `set hw.pci.enable_msix=0'
3. Enter in `boot'.
This will disable all MSI/MSI-X support (they're more advanced mechanism for receiving PCI interrupts). This might cause issues at boot though, depending on the motherboard architecture.
At that point if none of the above methods help or resolve the issue, I would look at issues with interrupt sharing in the BIOS (it's probably not doable because it's a desktop chipset and they tend to dumb that stuff down a bit, but you never know..).
Screenshots for each procedure would help a lot.