OK.
Another Maxtor 120 has failed on me, at 13 months of course. Turned on the TV to find it in a "Welcome! Powering up" loop.
After much crying (it *is* premiere week!

), decided to run out and get a drive and investigate my options. I had about 60 shows on there that were either about to be archived, or not yet watched.
Ended up getting a 200 GB WD (3-year warranty) to keep my options open. Decided to try dd_rescue and downloaded a Knoppix 3.9 Live CD. First I made a standard MFS_Tools 2.0 backup just to be safe.
I used the command as indicated in PP's updated post above, and it cruised along until hitting its first bad blocks at about 33 G. I let it go for a bit, then rebooted and invoked it again, this time to go in reverse. It flew along, transferring 45 G before the first errors. I went away for an hour and came back to find it was in good sectors again, so I rebooted and used the -s xxxxxxxxk flag to get it to start where it left off. I had to do this twice in all. I woke up this morning and the copy was complete, with a total of 1200K of errors. I figure my chances are good.
I popped the new 200 GB drive in the DSR6000 and booted up fine. I watched a bit of live TV and checked Now Playing to see that all my shows are there. I left for an appointment.
When I came home after a couple of hours, I was on a GSOD. I plugged in the Ethernet cable. After about 10 minutes, it tried to boot up. It gets through the CacheCard boot, to "Almost there..." then back to GSOD. This has repeated several times now in the hour I've been here.
Is TiVo trying to repair the null blocks, or is something else wrong? Should I let it keep cycling like this, or just give up on my recordings and SPs and just restore the MFS Tools image?