Thanks for the input.
- "Does the Firewire connection seem OK generally"
Yes, but just in case I used a different cable for the 2nd attempt, which also failed.
- "You may have log entries from the time of the failure"
I did grab the log just in case, although I'm not really up to speed on what it all means. Details below.
As seen in the log I also tried using the partition option to reformat, and that failed too, but just the once. I tried it a few more times and it worked fine.
So after one of the successful reformats, I dragged a bunch of files onto the drive and they seemed to copy over fine. Then out of curiosity I ran DiskWarrior, and it found no errors. I ran Disk Utility's First Aid again and it found nothing wrong either. I suppose I could try starting Time Machine again and keep a close eye on it over the next while.
2014-12-05 22:31:11 -0800: Disk Utility started.
2014-12-05 22:32:15 -0800: Preparing to erase : “Untitled”
2014-12-05 22:32:15 -0800: Partition Scheme: GUID Partition Table
2014-12-05 22:32:15 -0800: 1 volume will be created
2014-12-05 22:32:15 -0800: Name : “Untitled”
2014-12-05 22:32:15 -0800: Size : 4 TB
2014-12-05 22:32:15 -0800: File system : Mac OS Extended (Journaled)
2014-12-05 22:32:15 -0800: Unmounting disk
2014-12-05 22:32:15 -0800: Creating the partition map
2014-12-05 22:32:16 -0800: Waiting for the disks to reappear
2014-12-05 22:32:16 -0800: Formatting disk1s2 as Mac OS Extended (Journaled) with name Untitled
2014-12-05 22:32:31 -0800: Initialized /dev/rdisk1s2 as a 4 TB case-insensitive HFS Plus volume with a 311296k journal
2014-12-05 22:32:31 -0800: Mounting disk
2014-12-05 22:32:33 -0800: Erase complete.
2014-12-05 22:32:33 -0800:
2014-12-05 22:33:16 -0800: Preparing to zero disk : “Time Machine HD”
2014-12-05 22:33:16 -0800: 1 Pass Secure Erase
2014-12-06 14:56:27 -0800: Secure Disk Erase failed with the error:
Securely erasing data to prevent recovery failed.
2014-12-06 14:56:28 -0800: Preparing to erase : “Time Machine HD”
2014-12-06 14:56:28 -0800: Partition Scheme: GUID Partition Table
2014-12-06 14:56:28 -0800: 1 volume will be created
2014-12-06 14:56:28 -0800: Name : “Time Machine HD”
2014-12-06 14:56:28 -0800: Size : 4 TB
2014-12-06 14:56:28 -0800: File system : Mac OS Extended (Journaled)
2014-12-06 14:56:28 -0800: Error with partition Assert: internal error or unimplemented
2014-12-06 14:56:28 -0800: Erase complete.
2014-12-06 14:56:28 -0800: