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I'm so sorry to read this.
Something similar happened to me some months ago... after hours and hours of different tests I finally let the device to run out the battery completely (2 weeks), then I've prepared a new formatted SD card with original firmware (2.0RC3 I think), and connect the power to a wall-charger, after an hour I switched on the device and it worked, performing the upgrade.
As you mentioned IREX said it's not posible to brick the device, I can imagine breaking the screen with some malformed refresh calls but this is not the same.
So let's the device run out of battery completely and repeat the process.
Well, hope your DR800 will recover.
Iņigo
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