He currently has 3 partitions, but Rockbox can only write to 1. What I'm suggesting is combining 2 of the 3 partitions (the 2 good ones via re-partitioning) so that there becomes a total of 2, and let Rockbox write to the good one that does not have bad sectors. Is that not feasible?
I really should have to look at the code, but iirc Rockbox will try to use the first FAT partition it encounters. And partitions are in one piece, so no gaps in the middle
I was assuming that if you had 2 partitions on a drive and 1 had bad sectors, you would treat the partition that you wanted to access via Rockbox as the 'root folder' and place the rockbox folder & bootloader in there. I haven't ever tried to isolate bad sectors by partitioning though, so I don't know.
Thats what I did. After partitioning into 3 parts, the drive that tested 100% I put as the ROOT and dumped all Rockbox stuff on it.
When booted up, It loaded up that partition perfectly fine. I can only access the other partitions via the PC USB, but if I wanted, I could boot it off another partition my changing the ROOT and where I dump the Rockbox files.
I could also easily combine the 2 'good' partitions to 1 and boot from that, but I'm more than happy with the 6gb and 10 hour recording time.