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I NEVER record more than 16 Tracks to one 250 GB drive.
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The capacity has little to do with how many tracks can be recorded at once; however, I ALWAYS record to an empty drive and let the capacity be a deciding factor on how long I can safely record on single pass. I too agree that hard drives shouldn't be used to their full capacity, especially on a live situation which doesn't forgive any mistakes.
A regular 7200rpm hard drive can easily take 32 tracks, and a faster 10krpm even more. Just start with empty drive so the system can optimize the writing process. It will also help if you can limit the recording time to for example 90 minutes or so (one file fits into one cd or six files into one dvd, or however you wish to backup), which means that files that can hold the whole 90 minutes will be allocated from the disk before anything gets streamed into the files.
Yep. Empty drive is your friend when you record live gigs.