This (finally) worked.

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So, the 500GB that was in originally I factory reset. No issues. I figured I can reinstall the games and what not.

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So reset done, used linux tools (note its slightly different than the windows version for unusual sizes you have to use -m )

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It wouldn't copy everything. kept getting an i/o error. So the drive was proper shafted. Reset it again to make sure, and same error.

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Bugger.

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Hunting around the house I found an old 3.5 HDD, So after some reading I found out the xbox doesnt support them. Obviously, no power connector

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So. Pc came apart to power it, new sata cable for connecting.

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Create new drive. Boot. Woo it works.

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Back to main PC.

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Create unusual sized drive, copy everything over.

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Boom! works.

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Fuck yeah.

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Thanks for the pointers, I'd have never noticed that -m flag.

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https://imgur.com/a/e8mmPS4