A couple ideas:
- The HTML you are trying to use has some errors in it that Calibre can't entirely fix up on its own into valid XHTML. So the ePub parser gags on it when it reaches the error and simply refuses to render the rest. Page numbering gets screwed up by this as well (the page count is 'correct', but the final page is where the error is, not at the end of the book).
- Although not as likely, if Calibre is set to not auto-split the HTML files there could be issues. ePub has a 300KB limit per HTML file on devices that use Adobe's SDK (nook, Sony Readers, etc).
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