[format] fixed corruption issue when MBR is garbage

* after a bb check, MBR could become garbage
* when that occurs, Windows might interpret a bad partition table and prevent MBR from being properly written
* force a complete zeroing of the whole MBR before partitioning to fix this
* also added error code for bb

src/br.c

@@ -189,3 +189,9 @@ int write_zero_mbr(FILE *fp)
       write_data(fp, 0x0,   mbr_zero_0x0, sizeof(mbr_zero_0x0)) &&
       write_data(fp, 0x1FE, aucRef, sizeof(aucRef));
 } /* write_zero_mbr */
+
+int clear_mbr(FILE *fp)
+{
+	unsigned char buf[512] = { 0 };
+	return write_data(fp, 0x0, buf, sizeof(buf));
+} /* clear_mbr */

src/format.c

@@ -212,6 +212,16 @@ static BOOL AnalyzeMBR(HANDLE hPhysicalDrive)
 	return TRUE;
 }
 
+
+static BOOL ClearMBR(HANDLE hPhysicalDrive)
+{
+	FILE fake_fd;
+
+	fake_fd._ptr = (char*)hPhysicalDrive;
+	fake_fd._bufsiz = SelectedDrive.Geometry.BytesPerSector;
+	return clear_mbr(&fake_fd);
+}
+
 /*
  * Process the Master Boot Record
  */
@@ -335,11 +345,20 @@ void __cdecl FormatThread(void* param)
 			SelectedDrive.Geometry.BytesPerSector, BADBLOCKS_RW)) {
 			// TODO: report block failure number, etc
 			uprintf("Bad blocks check failed.\n");
+			FormatStatus = ERROR_SEVERITY_ERROR|FAC(FACILITY_STORAGE)|APPERR(ERROR_BADBLOCKS);
 			goto out;
 		}
 		safe_unlockclose(hLogicalVolume);
 	}
 
+	// Especially after destructive badblocks test, you must zero the MBR completely
+	// before repartitioning. Else, all kind of bad things happen
+	if (!ClearMBR(hPhysicalDrive)) {
+		uprintf("unable to zero MBR\n");
+		FormatStatus = ERROR_SEVERITY_ERROR|FAC(FACILITY_STORAGE)|ERROR_WRITE_FAULT;
+		goto out;
+	} 
+
 	if (!CreatePartition(hPhysicalDrive)) {
 		FormatStatus = ERROR_SEVERITY_ERROR|FAC(FACILITY_STORAGE)|ERROR_PARTITION_FAILURE;
 		goto out;

src/inc/br.h

@@ -72,4 +72,8 @@ int write_syslinux_mbr(FILE *fp);
    FALSE */
 int write_zero_mbr(FILE *fp);
 
+/* Completely clears (zeroes) master boot record, returns TRUE on success, otherwise
+   FALSE */
+int clear_mbr(FILE *fp);
+
 #endif

src/rufus.c

@@ -742,7 +742,7 @@ static INT_PTR CALLBACK MainCallback(HWND hDlg, UINT message, WPARAM wParam, LPA
 		if (IsChecked(IDC_QUICKFORMAT)) {
 			SendMessage(hProgress, PBM_SETMARQUEE, FALSE, 0);
 			SetWindowLongPtr(hProgress, GWL_STYLE, ProgressStyle);
-			// This is the only way to achieve instantenous progress transition
+			// This is the only way to achieve instantanenous progress transition
 			SendMessage(hProgress, PBM_SETRANGE, 0, 101<<16);
 			SendMessage(hProgress, PBM_SETPOS, 101, 0);
 			SendMessage(hProgress, PBM_SETRANGE, 0, 100<<16);

src/rufus.h

@@ -183,3 +183,4 @@ typedef struct {
 #define ERROR_INVALID_CLUSTER_SIZE     0x1203
 #define ERROR_INVALID_VOLUME_SIZE      0x1204
 #define ERROR_CANT_START_THREAD        0x1205
+#define ERROR_BADBLOCKS                0x1206

src/rufus.rc

@@ -30,7 +30,7 @@ LANGUAGE LANG_ENGLISH, SUBLANG_NEUTRAL
 IDD_DIALOG DIALOGEX 12, 12, 206, 278
 STYLE DS_SETFONT | DS_MODALFRAME | DS_FIXEDSYS | WS_POPUP | WS_CAPTION | WS_SYSMENU
 EXSTYLE WS_EX_APPWINDOW
-CAPTION "Rufus v1.0.2.79"
+CAPTION "Rufus v1.0.2.80"
 FONT 8, "MS Shell Dlg", 400, 0, 0x1
 BEGIN
     DEFPUSHBUTTON   "Start",IDC_START,94,236,50,14
@@ -65,7 +65,7 @@ BEGIN
     DEFPUSHBUTTON   "OK",IDOK,231,175,50,14,WS_GROUP
     CONTROL         "<a href=""https://github.com/pbatard/rufus/wiki/Rufus"">https://github.com/pbatard/rufus</a>",IDC_ABOUT_RUFUS_URL,
                     "SysLink",WS_TABSTOP,46,47,114,9
-    LTEXT           "Version 1.0.2 (Build 79)",IDC_STATIC,46,19,78,8
+    LTEXT           "Version 1.0.2 (Build 80)",IDC_STATIC,46,19,78,8
     PUSHBUTTON      "License...",IDC_ABOUT_LICENSE,46,175,50,14,WS_GROUP
     EDITTEXT        IDC_ABOUT_COPYRIGHTS,46,107,235,63,ES_MULTILINE | ES_READONLY | WS_VSCROLL
     LTEXT           "Report bugs or request enhancements at:",IDC_STATIC,46,66,187,8
@@ -164,8 +164,8 @@ END
 //
 
 VS_VERSION_INFO VERSIONINFO
- FILEVERSION 1,0,2,79
- PRODUCTVERSION 1,0,2,79
+ FILEVERSION 1,0,2,80
+ PRODUCTVERSION 1,0,2,80
  FILEFLAGSMASK 0x3fL
 #ifdef _DEBUG
  FILEFLAGS 0x1L
@@ -182,13 +182,13 @@ BEGIN
         BEGIN
             VALUE "CompanyName", "akeo.ie"
             VALUE "FileDescription", "Rufus"
-            VALUE "FileVersion", "1.0.2.79"
+            VALUE "FileVersion", "1.0.2.80"
             VALUE "InternalName", "Rufus"
             VALUE "LegalCopyright", "© 2011 Pete Batard (GPL v3)"
             VALUE "LegalTrademarks", "http://www.gnu.org/copyleft/gpl.html"
             VALUE "OriginalFilename", "rufus.exe"
             VALUE "ProductName", "Rufus"
-            VALUE "ProductVersion", "1.0.2.79"
+            VALUE "ProductVersion", "1.0.2.80"
         END
     END
     BLOCK "VarFileInfo"

src/stdio.c

@@ -192,6 +192,8 @@ const char* StrError(DWORD error_code)
 		return "Cancelled by user";
 	case ERROR_CANT_START_THREAD:
 		return "Unable to create formatting thread";
+	case ERROR_BADBLOCKS:
+		return "Bad blocks detected";
 	default:
 		uprintf("StrError: hit default - %08X\n", error_code);
 		SetLastError(error_code);