update:
At this point I have tried 4 different 4516s and they all are giving me the same problem. After I format the compact flash in the 4516 and transfer them to my pc's card reader to load the image on the flash card Windows is telling me that the disk needs to be formatted even though I just formatted it on the 4516s. So, I tried formatting on the pc and then I load the image on the CF and insert it into the 4516s and try to copy the image onto the bootflash: it gives me this error
"%Error opening slot0:/ (Bad device info block)". It's just and endless loop of these steps.
I have used this method a million times before on sup720s, sup6s, sup7s etc and I have never once encountered this problem. I'm on the verge of pulling my hair out at this point because I am absolutely stumped.