Firstly I don't want your $50, make it $100 and the info is yours! LOL
Heres where I feel you are going wrong with the hotswapping:
Don't hotswap at X3Config Live, don't hotswap at Flashbios - this isn't really going to do you any good.
This is what I would do:
1) Go to XBINS and get the file FLASHX3.
2) Install this app on your brothers XBOX and put the 1959 or 1959v16 bios in the apps bios folder. The bios file does not have to be renamed to anything, just leave as is.
3) Make sure your brothers default dashboard is capable of launching the flash X3 application.
4) Reboot your brothers xbox to his default dashboard.
5) Now, obviously being careful - put your chip in his xbox box. It must be left at his default dashboard, also make sure your flash protect switch is off on the chip itself.
6) Launch FLASH X3.
7) Reflash you chip - it's all self explanatory with on screen instructions.
8) Shut down his XBOX, take your chip out, put it back in your xbox and you should be OK>
Let me know how you get on!!!!!