Anyone know what has happened here?
I downloaded the AV8B/GR7/T10, set up a Fs9 folder amd placed the first 2 in it. All appeared in the aircraft selection, I fiddled with the thumbnails and names, retextured the grey GR7 to green, all worked, but the HUD was opaque.
So today I found another FS2004 AV8B panel, renamed the original, and put the new one in. Started to get all the 'unsupported' messages, so exited, deleted the new panel and replaced the one that worked yesterday. No GR7 in the selection. Removed GR7 folder to a temp folder, rebooted and replaced it in Fs9. Still no show. FSX will not even allow me to delete everything from the computer and reinstall it from the zip on a CD.
Does FSX have a 'blacklist'? Does it remember?

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Right. I assume you're talking about the Alphasim Harrier set here. http://www.simviation.com/fs2004military124.htm
I downloaded the file to check it out. This is configured as 3 separate aircraft with the following folder names:
ALPHA Harrier AV-8B
ALPHA Harrier GR7
ALPHA Harrier T10

The AV-8B has a basic panel & will work on its own but the other two have their panels aliased to it. If the ALPHA Harrier AV-8B is not installed to the same directory as the others they will not display. You can easily overcome this by giving them their own panels.

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I still can't figure this out. It's only a small file. Why not download it again & install it like I did?

Aye, the cock up theory is about right, RB - took everything out and put everything in again from scratch and it worked. Didn't do anything obviously different, so no idea why it was ok this time.

A happy note - I like this sim, quirky though it might be. It runs smoothly on my fairly good machine, it looks like I will be able to tweak, add-on and fiddle about to my heart's content, and Scotland is beautiful to look at, even though the UK data seems to get some stick in the forum. No doubt the community will improve it, but FSX already puts a smile on my face.