The other issue I have is extremely slow disk access when using hardfiles, literally its as bad as sitting and waiting for the old 880k FD to load, I am not sure if this has been caused by the way I have formatted the volume, with FFS and Directory cache+international mode, perhaps people can share their experiences on this.. My hardfiles are both 800MB each.Hmmm. That's not good either.Hardfiles are damn quick here. I haven't tried directory-caching + international mode, but I don't see why that would make a huge amount of difference. I'll test here.
Directory cache is completely pointless with hard drives. (but I don't think it is the reason for your slowdown problem)