> Does anyone know what "errno = 27" is telling me ?

#define EFBIG   27      /* File too large                       */

EFBIG   Indicates that an attempt was made to write a file that exceeds
the file size of the process limit or the systemwide maximum file
size.

Try "ulimit -f" to see what your limit is. Then "ulimit -f {big#}" to make
bigger.