Sorry folks; I broke mail again, actually mx1 again late last night. I ran badblocks on the old drive and redirected the output to a file in /tmp. This exhausted /tmp and caused some delivery failures. I didn't expect the output to exceed 200MB but it did, about half-way through the drive there is a point where it fails solid, original problems definitely were hardware. I've removed the file, I took the system down briefly this morning and ran fsck forced on all the file systems just to be sure that no more file system corruption was taking place, all were clean.