Doesn't look protection is turned on. I used the commands from this page: Henderson's Law. Had issues with sg_format in the beginning, so I went the camcontrol route. Thought it was equivalent.First did you check smart(ctl) to make sure you do not have any protection enabled on the drive? Like type 2 protection. Even after changing the block type 2 protection will result in an input/output error when you try and write to the drive.
If you do that needs to be changed.
Did you only change the block size or did you change the block size and perform a low level format after the change?