What's the difference between not mounting and not working?

Identical in that it was recognized but you couldn't mount it. But the dmesg
from sd0 was clearly wrong. So I rebuilt everything.

If the output of your dmesg is incorrect, i.e.

sd0 at scsibus0 targ 1 lun 0: <Apple, iPod, 2.70> SCSI4 0/direct removable
sd0: 486MB, 62 cyl, 255 head, 63 sec, 512 bytes/sec, 996030 sec total

Showing a storage size of 0.5 GB, how is fdisk / disklabel going to show
anything different?

You don't need to amend anything via fdisk/disklabel on your ipod. The 3.7
kernel reads the hard disk just fine. A clean build is is in order.

4MB mini ipod
-------------
sd0 at scsibus0 targ 1 lun 0: <Apple, iPod, 1.62> SCSI0 0/direct removable
sd0: 3906MB, 3906 cyl, 64 head, 32 sec, 512 bytes/sec, 7999488 sec tota

% fdisk sd0
fdisk: sysctl(machdep.bios.diskinfo): Device not configured
Disk: sd0       geometry: 3906/64/32 [7999488 Sectors]
Offset: 0       Signature: 0xAA55
         Starting       Ending       LBA Info:
 #: id    C   H  S -    C   H  S [       start:      size   ]
------------------------------------------------------------------------
 0: 00    0   0  0 -    0   0  0 [           0:           0 ] unused      
*1: 0B   39  14  6 - 3898  37 17 [       80325:     7903980 ] Win95 FAT-32
 2: 00    0   0  0 -    0   0  0 [           0:           0 ] unused      
 3: 00    0   0  0 -    0   0  0 [           0:           0 ] unused

% disklabel sd0
disklabel: warning, DOS partition table with no valid OpenBSD partition
# /dev/rsd0c:
type: SCSI
disk: SCSI disk
label: iPod            
flags:
bytes/sector: 512
sectors/track: 32
tracks/cylinder: 64
sectors/cylinder: 2048
cylinders: 3906
total sectors: 7999488
rpm: 3600
interleave: 1
trackskew: 0
cylinderskew: 0
headswitch: 0           # microseconds
track-to-track seek: 0  # microseconds
drivedata: 0 

16 partitions:
#             size        offset  fstype [fsize bsize  cpg]
  c:       7999488             0  unused      0     0      # Cyl     0 -  3905 
  i:         80262            63  unused      0     0      # Cyl     0*-    39*
  j:       7903980         80325   MSDOS                   # Cyl    39*-  3898*

6MB mini ipod
-------------
sd0 at scsibus0 targ 1 lun 0: <Apple, iPod, 1.62> SCSI0 0/direct removable
sd0: 5859MB, 5859 cyl, 64 head, 32 sec, 512 bytes/sec, 12000556 sec total

% fdisk sd0
fdisk: sysctl(machdep.bios.diskinfo): Device not configured
Disk: sd0       geometry: 5859/64/32 [12000556 Sectors]
Offset: 0       Signature: 0xAA55
         Starting       Ending       LBA Info:
 #: id    C   H  S -    C   H  S [       start:      size   ]
------------------------------------------------------------------------
 0: 00    0   0  0 -    0   0  0 [           0:           0 ] unused      
*1: 0B   39  14  6 - 5859  41 11 [       80325:    11920230 ] Win95 FAT-32
 2: 00    0   0  0 -    0   0  0 [           0:           0 ] unused      
 3: 00    0   0  0 -    0   0  0 [           0:           0 ] unused 

% disklabel sd0
disklabel: warning, DOS partition table with no valid OpenBSD partition
# /dev/rsd0c:
type: SCSI
disk: SCSI disk
label: iPod            
flags:
bytes/sector: 512
sectors/track: 32
tracks/cylinder: 64
sectors/cylinder: 2048
cylinders: 5859
total sectors: 12000556
rpm: 3600
interleave: 1
trackskew: 0
cylinderskew: 0
headswitch: 0           # microseconds
track-to-track seek: 0  # microseconds
drivedata: 0 

16 partitions:
#             size        offset  fstype [fsize bsize  cpg]
  c:      12000556             0  unused      0     0      # Cyl     0 -  5859*
  i:         80262            63  unused      0     0      # Cyl     0*-    39*
  j:      11920230         80325   MSDOS                   # Cyl    39*-  5859*

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