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Why not just create a service to run the packaged software at boot?
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When running as a service the software doesn't activate the card (not sure why). Also we're trying to avoid using the software as much as possible, when a user logs on we dont really want the packaged software to be running.
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But that is just a load of BS really - I know for sure that atheros cards work fine without mains power when you run either Linux or FreeBSD 
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The card works fine when activated, but doesnt activate itself on boot. Ive tried reinstalling XP in hopes that it was just the built in software or drivers causing the issue but the exact same problem occured (with the latest version of the card drivers). Ive also found that the card wasn't activated when running from a linux live cd.
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As to the ioctl codes - that would be specfic to the OS and the driver. Maybe you could email atheros directly and if they can supply any specs. Don't hold your breath though as they won't give them to the open source crowd either!
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Yeah i guessed from the complete lack of codes available online that it would be a pain to get them, doubt atheros would be able to help. Im thinking as a last resort that i might have to debug the driver or the preinstalled software that actually succeeds in starting the card. Maybe i can watch how their software does it and copy, i may even find a dll i can use thats responsible for communicating with the driver.
If you have any tips on debugging drivers id love to hear from you, i have experience with debugging normal applications so im sure it wont be completely foreign to me. I know there might be legal issues with this but i have little choice.
Thanks for the help
Roo