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New Replacement was easy.
I put the new drive in a cheap Kingwin external USB enclosure and formatted it FAT32 with OS X (Disk Utility -> Erase -> MS-DOS Format). (XP will only format FAT32 to 32 GB.) I then used the instructions (in this thread) to install the new drive. It was pretty easy.

I then powered it up and .... It also hung on bootup, until I plugged in the power adapter. Then it spun up and everything seems fine. It's much quieter than the old 20 GB Hitachi drive that came with it.

I'm defragging the old 20 GB drive now. It seems fine.

It's looking like the rechargeable batteries in the Archos are marginal, and the 20 GB drive might have some problems, but it seems OK in an external USB enclosure.

I'll try RockBox when I get some time.

So far, so good...

Cheers,
Scott.
New Does it strike anyone else as odd..
..that you used a Mac to DOS work because windows won't?
--
Steve
[link|http://www.ubuntulinux.org|Ubuntu]
New Apparently Linux would have worked, too.
:-)

I'm not at all surprised. As an old OS/2 user, I'm used to these things.

I'm just glad I knew about the issue before I spent 3 hours trying to get Windows to do it....

Cheers,
Scott.
New :-)
--
Steve
[link|http://www.ubuntulinux.org|Ubuntu]
     Looks like I have my fun cut out for me. - (bepatient) - (14)
         Luck! And thanks for the pointer. -NT - (Another Scott) - (2)
             No problem. - (bepatient) - (1)
                 These trick eyes of mine... - (admin)
         Drive arrived yesterday. - (bepatient) - (1)
             Thats what I get for starting projects at 3am - (bepatient)
         My 20GB Archos Recorder has the click of death. - (Another Scott) - (6)
             Luck! -NT - (jb4)
             See my post to bepatient... - (imric)
             Replacement was easy. - (Another Scott) - (3)
                 Does it strike anyone else as odd.. - (Steve Lowe) - (2)
                     Apparently Linux would have worked, too. - (Another Scott) - (1)
                         :-) -NT - (Steve Lowe)
         Riiich - (imric) - (1)
             It's on my list of things to try. Thanks. -NT - (Another Scott)

You are delightfully evil. Come sit by me.
42 ms