Ok, this is VERY strange...
I decided to load up the untouched bootanimation.zip made by ZeliardM (
link), and the audio worked!!!
i've been messing with that for a while, didn't think reverting back to the original would do anything.
I'm very baffled by this....
anyways, I have modified ZeliardM's version to fix up the aspect ratio of the droid eye, and converted the images from png to jpg. This made the animation smoother.
bootanimation.zip (rapidshare)
Again, credit goes to ZeliardM for capturing the frames from the video, I just tweaked it a little. This worked with sound as well.
And for those that still have problems with your audio file, just copy the mp3 file into your "tools" directory (same place where "bootanimation.zip" goes), and push it to your phone using this:
adb push android_audio.mp3 /data/local
Hope this helps.