I also have had tons of errors trying to convert to LRF using Calibre. I haven't wanted to admit what I go through to convert books the way I like, but here goes:
I have an eBookwise, Cybook (which reads Mobipocket), and Sony (which is the one I use the most). So I always convert my books into all three formats.
I start by decrypting the book from whatever format it came it to HTML. The HTML is almost always not formatted the way I like, so I copy it into a new Word document. Then I format the book the way I like - including a book cover and book description at the top of the story - and save the book as an RTF. Because I like a little spacing between my paragraphs, I save a second file of the RTF without the extra spacing for converting to Mobipocket (since Mobipocket Creator automatically inserts space between paragraphs, and it's too much if my starting file has it too). Then:
I use ETI's ebook converter program to make my eBookwise IMP files directly from the first RTF.
I use Mobipocket Creator with the second RTF (without the extra space between paragraphs) to make the Mobipocket file for the Cybook.
Mobipocket Creator makes an HTML file (and linked image folder, if any) as a biproduct of the conversion process. I zip that HTML file (and linked image folder) and import that into Calibre, to make my Sony LRF (with images).
I don't get the errors with Creator's HTML files that I got with RTFs with Calibre. So far, I haven't had any luck making EPUBs from those files with Calibre, but the LRFs work just fine.
Oh, sure, I occasionally get some ... oddness. Once in awhile, the first paragraph of every chapter is centered, for example. And despite that I format my chapter headings as only BOLD, they always end up as BOLD ITALIC. Sigh. And I haven't found a san-serif font yet that will embed in Calibre for LRFs. (And I've tried it with every san-serif font on my computer!) But the books are very readable. I get the images I missed with the RTFs.
(And I don't have to figure out how to use Book Designer, which I'll admit stumps me!)
So, if you don't mind adding a couple of extra steps to your conversion process (and installing Mobipocket Creator), you could still create your LRFs with Calibre from your original RTFs - after they've been converted to HTML by Mobipocket Creator.
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