I'm on an Intel Mac running 10.4 at the moment, and the Bad Pixel Pro app for Intel Macs doesn't actually launch for me (I see it's icon in the dock for a moment and then it kills itself). Looking at its crash logs, I can see error lines indicating that I have version 5.0.0 of libiconv.2.dylib, and it requires 7.0.0, so I'll see if I can get MacPorts to help me out with that.
I did do a search of the whole SD card on my desktop for the term "bad", and only came up with the "badpixel.lua" script itself.
I did do some analysis of the badpixel.lua script itself (see
this thread), and while ewavr pointed out where the bad_tmp.bin file should be created in the source, I'm wondering if the package I got doesn't have that line added to the proper source file. That would make sense of the evidence that no bad_tmp.bin file is created anywhere, and the script is returning "255", the 'special flag' number, rather than a more random number.