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I have a 2TB WD (My Passport Ultra) external HDD that has developed bad sectors, and I want to continue using it for non-essential/non-critical storage (I fortunately recovered all data that was on the drive, so data recovery is not the issue). The SMART info tells me that there are more bad sectors than spare ones.

My question is how to proceed with "ring-fencing" these bad sectors.

I understand from other posts here that just re-formatting the HDD, and letting the OS take care of marking the sectors as bad, so not re-using them, is not a good solution.

It was suggested elsewhere that I could partition the HDD, so the bad sectors are outside the partition. Is this really feasible, and if so, how to "tell" the partition software which part to exclude?

I have of course researched this topic a bit before posting, but as often is the case, quite some contradictory or vague information out there :

  • Re: bad sectors : some claim that once you start having bad sectors, these will "propagate" (e.g. because a bad sector often (?) is related to something physically wrong on the platter surface, hence every time the head moves over that area, the head "jumps" a bit and creates additional bad sectors); others claim that bad sectors are just "normal" for HDDs, so either the HDD itself marks them and uses a spare sector, or you have to do this manually, e.g. with chkdsk, but in any case you can still reliably use the HDD;
  • Re: continue using the disk : some say the disk could die within seconds/minutes, others says you can still use the disk for years once the bad sectors are not used anymore;
  • Re: bad sectors and spares : the info seems quite inconsistent and inconclusive about when a HDD is actually not fit for use anymore. It seems that as long as the HDD itself (the firmware/controller?) manages the "replacement" of bad sectors with spare ones all is fine, and in the SMART data you can see which % of the spares have been used, and if below a threshold, all is "green"; but once the user is confronted with a bad sector (presumably because the sector became bad after data was written to it, and you get CRC errors?), it seems that the consensus is to go into semi-panic mode, clone/recover what can be recovered, and throw the HDD in the fire. I am just making up the numbers, but if there are a few hundred (thousand?) of spare sectors, and the first few hundred of bad sectors are considered "normal", why the next few hundred of bad sectors suddenly are such a drama ? There are millions of sectors on a HDD, so is this rational behavior, statistically speaking ?

Similar questions on SU:

So lots of information, but nowhere a clear answer on (i) whether it is actually possible to create a partition to omit all bad sectors (and so that the head does never touches that bad area anymore), (ii) whether this will mitigate the risk that more bad sectors will appear, and (iii) some guidance how to accomplish this with a good/quality partitioning software (e.g. how much buffer to leave around the bad sectors) (there are some specific tools out there to create partitions that omit bad sectors, but they do not seem very reliable to me, but again, maybe I am just ignorant).

EDIT (Nov 2018)
Other SU discussion about similar topic :How can I partition out damaged sectors on a HDD?

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    Throw it away. If it's failing it will never get better, the rest will fail too, it's only a matter of time. Don't waste the effort.
    – Tetsujin
    Commented Jan 23, 2018 at 18:01
  • @Tetsujin Thanks, this seems indeed the majority opinion, but I would like to better understand the "why". It is a rarely used (maybe that's why there are bad sectors?) good-brand/premium-feel (for whatever that's worth) 2TB disk, so even with 100GB of bad sectors, I would still be happy to have a functioning 1.9TB HDD if I could isolate/discard these bad sectors.
    – Peter K.
    Commented Jan 23, 2018 at 18:11
  • Thing is, you don't know why they're bad, nor ever will without a clean room & microscope... It doesn't make any kind of sense to nurse it. You would never trust it to put anything important on, so it becomes an advanced floppy disk sneaker-net substitute & nothing more.
    – Tetsujin
    Commented Jan 23, 2018 at 18:18
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    @Tetsujin I agree about the non-important part. I will anyway have to buy a new 2TB HDD for the important data, but I want to keep on using the old one as a "nice to have" to exchange lots of data, or just as a third back-up for music/photos or so.
    – Peter K.
    Commented Jan 23, 2018 at 18:41
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    What are the actual SMART numbers for reallocated, pending, and unrecoverable sectors? As for your why question: because bad sectors tend to develop logarithmically, so one or two and you may be OK for some time, but by the time you get a few hundred, the drive is well on its way to bricked.
    – psusi
    Commented Jan 23, 2018 at 19:09

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