Interesting about the drives.
Interesting about the drives. I have 5 of those Seagate 1.5s in a Sans Digital tower running on a Sil3132 card as JOBD without issue, I have another 5 in another Sans Digital tower running on a RR644 card as JOBD without issue, the 644 also has three other 5 bay towers one with 5 Hitachi 7200 2Tb, one with 5 mixed 2Tb (2 WD, 2 Samsung and 1 Hitachi) and a fourth 5 bay tower running 5 Hitachi 7200 3Tb 6gb Sata3 drives.
Since I replaced the raid controller on the Dell there have been no stalling issues and there were none on the HP.
It would really be interesting to just put on that USB drive you have and set it up as a source in Media Center (so the folder is properly defined) and then copy a couple of shows you know you had trouble with onto the USB drive.
That will show you rather quickly if you have a recording issue or not and if they play ok that will limit your detective work to your controller and how it works with your drives.
Do you have the ability to check any of the drive settings such a read ahead and write back cache?
John