[HTC Sensation XL] hannemaster:
Here are some of the errors which stop it from working correctly. For people who know a bit more about this stuff than we do.

What we do know is that it has something to do with Partitions/Filesystems/mmcblocks.

failed to open /sys/class/android_usb/android0/state: No such file or directoryThat's right according to the list below it doesnt exist - also the recovery that is working doesn't call to this path...

/sys/class # ls
ls
adsp htc_portlist msm_vidc_enc scsi_generic
audlpa i2c-adapter msm_vidc_reg scsi_host
backlight input mtd sound
bdi lcd net spi_master
block leds oncrpc switch
bluetooth mem optical_sensors timed_output
diag misc power_supply tty
firmware mmc_host ppp usb_composite
gemini msm_camera rfkill usb_device
graphics msm_kgsl rtc video_output
gyro_sensors msm_mdp scsi_changer
htc_accessory msm_rotator scsi_device
htc_acoustic msm_vidc_dec scsi_disk

E: Unknown volume for path [/system]

E: Unknown volume for path [/cache]

E: Unknown volume for path [/data]

E: Unknown volume for path [/cache/recovery/log]

E: Unknown volume for path [/cache/recovery/last_log]

E: Unknown volume for path [/cache/recovery/command]

E:Can't mount /cache/recovery/log

E:Can't mount /cache/recovery/log

E:Can't mount /sdcard/

E:Can't open /cache/recovery/log

E:Can't open /cache/recovery/last_log

When android is loaded this is the partition information:

rootfs / rootfs ro,relatime 0 0
tmpfs /dev tmpfs rw,nosuid,relatime,mode=755 0 0
devpts /dev/pts devpts rw,relatime,mode=600 0 0
proc /proc proc rw,relatime 0 0
sysfs /sys sysfs rw,relatime 0 0
/dev/block/mmcblk0p25 /system ext4 ro,relatime,user_xattr,barrier=1,data=ordered 0 0
/dev/block/mmcblk0p29 /data ext4 rw,nosuid,nodev,relatime,user_xattr,barrier=1,data=ordered,noauto_da_alloc 0 0
/dev/block/mmcblk0p30 /cache ext4 rw,nosuid,nodev,relatime,user_xattr,barrier=1,data=ordered 0 0
/dev/block/mmcblk0p31 /devlog ext4 rw,nosuid,nodev,relatime,user_xattr,barrier=1,data=ordered 0 0
none /acct cgroup rw,relatime,cpuacct 0 0
tmpfs /mnt/asec tmpfs rw,relatime,mode=755,gid=1000 0 0
tmpfs /mnt/obb tmpfs rw,relatime,mode=755,gid=1000 0 0
tmpfs /app-cache tmpfs rw,relatime,size=8192k,mode=755,gid=1000 0 0
none /dev/cpuctl cgroup rw,relatime,cpu 0 0
tmpfs /data/secure/data tmpfs rw,relatime,mode=755,gid=1000 0 0
htcfs /data/htcfs fuse.htcfs rw,nosuid,nodev,relatime,user_id=0,group_id=0,allow_other 0 0
/dev/block/vold/179:33 /mnt/sdcard vfat rw,dirsync,nosuid,nodev,noexec,relatime,uid=1000,gid=1015,fmask=0702,dmask=0702,allow_utime=0020,codepage=cp437,iocharset=iso8859-1,shortname=mixed,utf8,errors=remount-ro 0 0
/dev/block/vold/179:33 /mnt/secure/asec vfat rw,dirsync,nosuid,nodev,noexec,relatime,uid=1000,gid=1015,fmask=0702,dmask=0702,allow_utime=0020,codepage=cp437,iocharset=iso8859-1,shortname=mixed,utf8,errors=remount-ro 0 0
tmpfs /mnt/sdcard/.android_secure tmpfs ro,relatime,size=0k,mode=000 0 0DxDrmServerIpc /data/DxDrm/fuse fuse.DxDrmServerIpc rw,nosuid,nodev,relatime,user_id=0,group_id=0,allow_other 0 0

this is the recovery.fstab of the touch recovery:

# mount point	fstype	device	[device2] fstype2

/recovery	emmc	/dev/block/mmcblk0p21
/boot	emmc	/dev/block/mmcblk0p22
/cache	ext4	/dev/block/mmcblk0p30 NULL ext3
/data	ext4	/dev/block/mmcblk0p29 NULL ext3
/sdcard	vfat	/dev/block/mmcblk0p33 NULL
/system	cd senext4	/dev/block/mmcblk0p25 NULL ext3

unfortunately I can't run logcat when android is not booted. We need to know what commands are executed that return these errors.

for troubleshooting I first flashed "r1-recovery-clockwork-5.0.2.7-modaco-runnymede.img" and booted in recovery. than I opened an adb shell and executed the mount command that lists the currently mounted partitions. after that I did the same for "r2-recovery-clockwork-5.8.0.9-modaco-runnymede.img" and notice there is a difference. as you can see the R1 mounts the cache partition for some reason and R2 doesnt. see below.

[B]R1 (non touch - working)[/B]
E:\SensationXL\files>adb shell
~ # mount
mount
rootfs on / type rootfs (rw)
tmpfs on /dev type tmpfs (rw,relatime,mode=755)
devpts on /dev/pts type devpts (rw,relatime,mode=600)
proc on /proc type proc (rw,relatime)
sysfs on /sys type sysfs (rw,relatime)
[COLOR="Red"]/dev/block/mmcblk0p30 on /cache type ext4 (rw,nodev,noatime,nodiratime,barrier=1,data=ordered)[/COLOR]

[B]R1 (touch - not working)[/B]
E:\SensationXL\files>adb shell
~ # mount
mount
rootfs on / type rootfs (rw)
tmpfs on /dev type tmpfs (rw,relatime,mode=755)
devpts on /dev/pts type devpts (rw,relatime,mode=600)
proc on /proc type proc (rw,relatime)
sysfs on /sys type sysfs (rw,relatime)

@shingers5 - Have you tried relocking your device and going stock yet?

additional info gathered:

It seems while in recovery and using adb shell I can mount any partition except for the sdcard. It's seems kinda logic, to make a backup or restore you need the sdcard.

according to the partition table inside the recovery sdcard should be on address:

/dev/block/mmcblk0p33 /sdcard

when android is booted and I list mounted partitions it says:

/dev/block/vold/179:33 /mnt/sdcard

both addresses won't mount.

>> New info

using the following command I can mount the sdcard and access it(from adb shell, while phone is in touch recovery), allthough recovery keeps telling me it cant mount sdcard..

mount -t vfat /dev/block/mmcblk0p33 /sdcard -o rw,nodev,noatime,nodiratime,fmask=0000,dmask=0000,allow_utime=0022

So without the extra options (rw,nodev,noatime,nodiratime,fmask=0000,dmask=0000,allow_utime=0022) sdcard won't mount.

I'm feeling i'm getting closer to the point to where I'll give up and just sit and wait for a pro. ah well atleast I gained some knowledge about all this ^^