This is an external drive, formerly a boot drive which is now in use only to access music files (sibelius, audio, midi, live, logic etc.) without transferring the data into a new boot system, partly because of the issue I am about to describe, but mostly because the majority of the data is mainly there for archival purposes. The user is a composer and prominent musician and needs to be able to rehash the data at will.

I have tried several things - here is a list:
- make complete filesystem clone with antonio diaz's ddrescue
- run Disk Warrior on copy, repair whatever errors occurred
- wipe out all ACLs on entire drive
- set all permissions to the same value - wide open 777
- remove any system data (applications, system files, including hidden files to the best of my knowledge) by selecting only non-system/app data and using Carbon Copy Cloner to put only the data of interest onto a newly formatted drive
- transfer data to newly formatted drive folder by folder, resetting the spotlight index in between adding each to observe for issues (interesting here is that no issues occurred except for in Documents folder - when I transferred only the Documents folder to a newly formatted drive on its own - no trouble. It appears almost as thought it may not be the content but the quantity or specific combination of data that results in problems)
- use DataRescue to transfer the data to yet another newly formatted drive to expose any missed hidden files

Between each of the above steps I stopped Spotlight (search for anything beginning with md in Activity Monitor - All Processes and quitting it), deleted the .Spotlight-V100 directory from the affected drive. Restart Splotlight indexing by adding drive to Spotlight privacy list and removing it.

In each case the same issue occurs - Spotlight begins indexing normally (or so it seems), then the index estimated time increases, usually to 4 hours remaining. This is where it gets stuck and continues to predict 4 hours remaining but never finishes. Sometimes I can't eject the drive and have to quit the md.. processes from Activity Monitor to be able to eject the drive without Force Eject. Once I disconnect the drive after the 4 hours remaining situation - if I reattach it, Spotlight forever estimates remaining time and never gets going again.

So there it is.

It is apparently not a filesystem issue, not a permissions issue and not tied to any particular piece of hardware or protocol (used USB and FW drives). I have tried this on several machines (3 to be precise) and in 10.5.8 and 10.6.5.

Simply disabling Spotlight on this volume is not an option because the owner has no clue where things are as the data on the volume dates back to music projects and compositions from 2003 and before. He needs to be able to query for results.

Anyone got any ideas?

Thanks,

M