It took almost exactly 3 hours to low-level format the 40GB.
One-third down the road, the disk was making all sorts of beeping and squealing noises, while the 'rotten' part was being treated.
This is the log report:
05/05/2007 13:51:13 * * * * * WARNING!!! * * * * *
05/05/2007 13:51:13 DURING THE LOW LEVEL FORMAT PROCESS
05/05/2007 13:51:13 ALL DATA WILL BE FULLY and IRREVERSIBLY ERASED!
05/05/2007 13:52:14
05/05/2007 13:52:14 =================================================
05/05/2007 13:52:14 Hard Disk Low Level Format Tool 2.36 build 1181;
http://hddguru.com
05/05/2007 13:52:14 Low level format: Generic USB Disk 9.02 [40 Gbytes]
05/05/2007 13:52:14 Device size: 78,140,160 sectors
05/05/2007 15:23:57 Format Error occured at offset 21,318,074,368
05/05/2007 15:24:06 Format Error occured at offset 21,318,598,656
05/05/2007 15:24:16 Format Error occured at offset 21,319,122,944
05/05/2007 15:25:16 Format Error occured at offset 21,319,647,232
05/05/2007 15:25:29 Format Error occured at offset 21,320,695,808
05/05/2007 15:25:39 Format Error occured at offset 21,321,220,096
05/05/2007 15:26:28 Format Error occured at offset 21,321,744,384
05/05/2007 15:26:42 Format Error occured at offset 21,322,268,672
05/05/2007 15:27:45 Format Error occured at offset 21,322,792,960
05/05/2007 15:28:15 Format Error occured at offset 21,323,317,248
05/05/2007 16:51:54 Low-level format is done. You will have to create partitions and format this drive.
I'll have to find out now if those sectors were marked as BAD or not. I'll first check it with Partition Magic before I partition/format.