[robkampen]

After having my previous iteration of * and zaptel up for 790 days I had to take it down to shift it, so I thought time to upgrade.
So new CentOS 5.5 and rpms from digium and asterisk I now have
Asterisk 1.6.2.7 currently running on asterisk1 (pid = 18562)
dahdi 2.3.0 running with a rhino R4FXO-EC card.
most stuff now working.
SIP phones can call each other, voicemail works, and incoming calls from the PSTN via the FXO card also work.
Problem is that outgoing calls to the PSTN via
-- Executing [4078764854@intern:1] Dial("SIP/6342-0000000b", "DAHDI/r1/4078764854") in new stack gives:
[May 30 22:44:05] WARNING[18778]: app_dial.c:1747 dial_exec_full: Unable to create channel of type 'DAHDI' (cause 0 - Unknown)
== Everyone is busy/congested at this time (1:0/0/1)
-- Auto fallthrough, channel 'SIP/6342-0000000b' status is 'CHANUNAVAIL'

a dahdi_scan shows:
[1]
active=yes
alarms=OK
description=Rhino RCB4FXO/1
name=Rhino RCB4FXO/1
manufacturer=Rhino
devicetype=
location=
basechan=1
totchans=4
irq=0
type=analog
port=1,FXO
port=2,FXO
port=3,FXO
port=4,FXO

dahdi/system.conf:
fxsks=1-4
loadzone = us
defaultzone=us

chan_dahdi.conf :
[trunkgroups]

[channels]
context=from-pstn
signalling=fxs_ks
channel => 1
usecallerid=yes
hidecallerid=no
callwaiting=yes
usecallingpres=yes
callwaitingcallerid=yes
threewaycalling=yes
transfer=yes
canpark=yes
cancallforward=yes
callreturn=yes
echocancel=yes
echocancelwhenbridged=yes

group=1
callgroup=1
pickupgroup=1

immediate=no
callerid = asreceived
busydetect=yes
busycount=6
ringtimeout=18000

and finally extensions.conf :
[general]
static=yes
writeprotect=yes
clearglobalvars=no

[globals]
ROB1=SIP/6344
MYNAME=Rob Kampen

CALLFILENAME=foo
FOO=foo

TRUNK=DAHDI/r1
TRUNKMSD=0

[congest-sip]
exten => _X.,1,Congestion

[from-pstn]
include => welcome
include => default

[trunkint]
exten => _011.,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:${GLOBAL(TRUNKMSD)}})

[trunkld]
exten => _1407NXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:1})
exten => _1321NXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:1})
exten => _1NXXNXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:${GLOBAL(TRUNKMSD)}})

[trunklocal]
exten => _407NXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:0})
exten => _321NXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:0})
exten => _352NXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:0})
exten => _386NXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:0})
exten => _863NXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:0})

[trunktollfree]
exten => _1800NXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:${GLOBAL(TRUNKMSD)}})
exten => _1888NXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:${GLOBAL(TRUNKMSD)}})
exten => _1877NXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:${GLOBAL(TRUNKMSD)}})
exten => _1866NXXXXXX,1,Dial(${GLOBAL(TRUNK)}/${EXTEN:${GLOBAL(TRUNKMSD)}})

[international]
include => longdistance
include => trunkint

[longdistance]
include => local
include => trunkld

[local]
include => trunklocal
include => trunktollfree
include => default
include => parkedcalls

[macro-trunkdial]
exten => s,1,Dial(${ARG1})
exten => s,n,Goto(s-${DIALSTATUS},1)
exten => s-NOANSWER,1,Hangup
exten => s-BUSY,1,Hangup
exten => _s-.,1,NoOp

exten => s,n,GoToIf([${AVAILSTATUS} = "1"]?autoanswer:fail)
exten => s,n,Page(${ARG1}||)
exten => s,n(fail),Hangup

<snip>
[welcome]

include => default
exten => #,n,Goto(s,5)

exten => t,n,Hangup
exten => i,n,Goto(s,6)
exten => *,1,Directory(intern,default)
exten => *,n,Hangup

exten => 8500,1,VoicemailMain(@intern)
exten => 8500,n,Goto(s,6)

[page]
exten => _X.,1,Macro(page,SIP/${EXTEN})

[default]

exten => s,1,Playback(thank-you-for-calling)
exten => s,n,Hangup

exten => 6344,hint,SIP/6344
exten => 6344,1,Macro(stdexten,${EXTEN},${GLOBAL(ROB1)})
exten => rob,1,Goto(6344|1)
exten => rkampen,1,Goto(6344|1)

exten => 1230,1,Dial(SIP/1230,20)
exten => 1230,2,Voicemail(1230@intern)
exten => 1230,102,Voicemail(1230@intern)
exten => 1230,103,Hangup

exten => 701,1,ParkedCall(701)
exten => 701,hint,park:701@parkedcalls
exten => 701,2,noop
exten => 702,1,ParkedCall(702)
exten => 702,hint,park:702@parkedcalls
exten => 702,2,noop
exten => 8500,1,VoicemailMain(${CALLERID(num)}@intern)
exten => 8500,n,Hangup
exten => 8600,1,Meetme(8601,i)
exten => 8600,n,Hangup
exten => 8601,1,Playback(conf-thereare)
exten => 8601,n,MeetMeCount(8601)
exten => 8601,n,Playback(conf-peopleinconf)
exten => 8601,n,Hangup

I've probably given more detail than necessary but hopefully someone can see what I'm missing that prevents outgoing calls from working.

[robkampen]

Looking through many more google searches I tried
exten => _9,1,Dial(DAHDI/1)
and then manually dialed out after getting dial tone - no problems IT WORKS
so long story short the problem is when I use any of the trunk hunting prefixes
r,R,g,G - it fails
i.e. DAHDI/r1 fails
just using DAHDI/1 works fine, however I don't know what this means in terms of selecting one of my three lines - as I understand it the 1 (one) refers to the group number defined in chan_dahdi (which is 1).
Any ideas out there?
TIA