It sounds like

        cannot add sd12!plan9 [63,156296385] to disk [0,976937355): partition 
boundaries out of range

is coming from 9load.  I haven't seen this, but it does sound like
garbled partition tables or a bad disk.  The first block of a file
system contains its configuration block, so if you plan to have an MBR
or other DOS/FAT stuff on the disk, you'll need to skip it.  I do that
on my main file server to allow a small DOS partition.  To do so, use
p(w0)1.99 instead of w0, for example.

`panic: fworm: checktag 6105775' is quite serious.  The fake-worm
bitmap isn't initialised.  Copying fworms is tricky, particularly if
the output device is larger than the input device.  You probably ought
to use copyworm instead of copydev, since copydev just blindly copies
blocks, assuming input and output are the same size, but copyworm
knows how to copy fworms, including reaming the output fworm, thus
creating its bitmap.

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