I have seen problems like this with large files on multiple fs's and ultimately it was a RAM problem. Scott, can you run memtester and/or memtest86 at bootup to verify that you don't have bad RAM? Is your CPU overclocked? CPU errors can also be detected with burn* programs (cpuburn package). A rare RAM problem can cause bitflips that you wouldn't notice except in large files.
I have seen problems like this with large files on multiple fs's and ultimately it was a RAM problem. Scott, can you run memtester and/or memtest86 at bootup to verify that you don't have bad RAM? Is your CPU overclocked? CPU errors can also be detected with burn* programs (cpuburn package). A rare RAM problem can cause bitflips that you wouldn't notice except in large files.