I've done more testing, and this is even worse than I thought.

 If a filesystem fails fsck (tested by rolling clock back a week), the
recovery shell does NOT spawn and you CANNOT run fsck manually. If I do
this on the console, I do not get any message from Init about mountall
stopping, only a message about fsck's exit status. On an esc press
against a waiting mountall, I get mountall:cancelled instead of a
message from init about mountall ending. SAME message if I try to cancel
a root filesystem fsck run.

I think two things are happening here:

1: It looks like Mountall isn't actually EXITING, thus no "start on mountall 
stopped" process launches, and with mountall in an "infinate delayed exit," 
init simply waits-forever.  I put a variety of test scripts in set to start on 
stopped mountall-and not one of them would launch. I then set a script to start 
on startup, stop mountall, shut down the splash screen, run /sbin/sulogin , 
then restart mountall, and this worked as written. 
This means you can spawn a shell, but the trigger for mountall-shell.conf 
(mountall stopped) is not getting sent.

2: On a root filesystem fsck run, an esc press gets detected by mountall
and treated as "cancel mountall", while on an non-root filesytem fsck
run, mountall stops fsck but is not itself cancelled. Perhaps the
internal variable on mountall responding to an Esc press is being
improperly set during root fsck runs only?


  If you install karmic on a cheap flash drive or any other circumstance where 
frequent filesystem corruption is a fact of life, there are two solutions: 
either set all fsck pass numbers to 0 and check it at intervals on another 
system, or open /etc/default/rcS and set FSCKFIX=yes . The danger of the latter 
is data loss in a severe filesystem corruption case before you get to make any 
decisions about recovering data first, then fixing the filesystem.

-- 
Recovery shell does not spawn if mountall stopped by esc (mountall 1.0)
https://bugs.launchpad.net/bugs/476161
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