Okay here's my theory: people have reported that if the HR20 loses signal it truncates the recordings, sometimes leaving them as partials and unplayable, sometimes not (though it's been awhile since the rash of "Rain Fade Killed My Recordings!" threads). Perhaps you have an intermittent signal issue - wind or rain affecting the dish, coax or multiswitch starting to go bad, etc. I would seriously look into those issues before you listen to those who advocate dumping the box in a landfill.
Alternately, and if this is it, blame it squarely on a bug in the HR20. Padding recordings doesn't seem to work well AT ALL. Just click the entry in the guide and record it that way with no padding and see if that helps.
Alternately, and if this is it, blame it squarely on a bug in the HR20. Padding recordings doesn't seem to work well AT ALL. Just click the entry in the guide and record it that way with no padding and see if that helps.