Hi Saratoga,
...and since writing to internal flash is also unreliable when using rockbox
and fine when using the OF I think that there is definitely something with
the rockbox flash/usb driver which could be -hrrrmm- changed (at least)

To summarize the adventure here again is only for the purpose of makeing
it easier for others to find a solution.
Player: Sansa Clip ZIP bought April/May 2014
Rockbox: Stable and current developper builds.
Symptoms:
Database initializing and updates hang or crashes the player.
Longer songs (~20minutes) and sometime even shorter Songs suddenly stop
and the player becomes unresponsive directly or after some clicks later.
Due to the need of doing "cold restarts" (pressing on/off for so long that the
shutdown is forced) lead to filesystem corruption of the external flash (bad)
and internal flash (worse).
This also effects the original software while shareing the same internal flash as
rockbox do. And writing to a corrupted filesystem is worst. Ask a UNIX sysadmin

What follows has worked for me. That does not mean, that it will work for
others...but why not to give it a try?
I am using Linux for all this and can only describe things related to it.
But I am shure, that other operating system will have similiar tools...
BIG FAT RED WARNING!Carefully select the <player device> (see below)!
Selecting the wrong one will definitely brick your player.
Before doing anything else try mounting the device. If it says
"no such device" or "device is write only" or similiar you have
choosen
the wrong oneKeep your hands off this device!
Each time you connect the player, check the device! Dont rely
on the nameing of the device being the same as last time you connected the player!
If you can mount the device and list its contents it is either
the internal flash (it contains the ".rockbox"-folder) or the
extern flash of your sdcard in the player.
How to check for a corrupted filesystem:
Do this only when the device is not mounted!
Unmount it, if it is mounted!
Select the correct device! (See above).
Use
fsck.vfat -n /dev/<player device>; echo $?to check the filesystem without doing any changes.
If it prompts "0" everything is ok, if there is a number greater than "0", then
the filesystem is damaged.
By removing any files, which were written after the last "ok" status of the filesystem
you can try to remove any questionable data.
AFTER doing so, try doing
fsck.vfat -a /dev/<player device>; echo $?.
Repeat until you get a "0" back.
If things are screwed up and you cannot trust the integrity of the
filesystem any more (still getting symptoms as described above) boot
into the original firmware, and format the according flash.
YES, you are allowed to format the internal flash. But do it
ONLYvia the original firmware!
DONT try using tools like mkfs.vfat or such alike!!!After that you:
Lost any data you put onto the flash drive.The filesystem is clean again.
When booting then you will get something like "
rockbox folder not found"
DON'T PANIC!Simply boot into the original firmware and install rockbox again. Don't
install the bootloader again though -- it is still in place.
If you still get sudden stopps of the playback, hangs, crashes and such
you have a sdcard in use which may be readable and writeable by the
original firmware but unfortunately it is not while using rockbox.
I bought a new card and up to this moment I am writing this the
problems are gone.
The card is a
32 GB TOSHIBA MICRO SDHC High Speed Professional Class 10 SD-C032UHS1
(19EUR)
May be one time the original firmware and rockbox are able to read and write
the same flash cards.
And:
Using a """bad""" external flash even seems to influence the capability of
rockbox to write to the internal flash. May be they are hanging on the same bus structure (I2C???)
or such??? ... dont know.
Again: This has worked for me. And this does NOT imply that it will work for you.
I cannot held responsible for damages which may result directly or indirectly from
applying what I have described. Therefore this help is given free of charge.
May the rockbox be with you, Luke!Best regards,
mcc