Petur, please read my post (above) again. I reported something incorrectly.
chkdsk says:
The size of the \recordings\R_MIC_071012-231825.wav entry is not valid.
dirchache is ON.
Hope this helps.
Rants & Ideas:
1) since the file's gonna get chopped anyway, why not throw away whatever is in the buffer and just write the end of the file politely?
2) Is there a way for the recording code to know how much space is left on Disk and simple report the amount of space available as {{ actual_freespace - 2*Buffer }}, or something similar? Essentially lie to the recording code about how much space is actually left.
3) If a file fails to play due to this type of corruption a splash screen should be displayed saying so instead of just playing the next file in the directory. In my case the files were of near silent background noise with very similar (date stamp) names so I thought the file played OK on the DAP when in fact it did not.
[edit] I jumped on IRC for a sec and had Mike S re-open FS#5852
Check it out:
http://www.rockbox.org/tracker/task/5852