Wow. Sorry I did not catch this thread earlier, but I was working last night...

There is a very specific bug that you only encounter when you are doing a fresh install of MASSIVE amounts of playlists. I have only encountered it when wiping out large hard drives and syncing tons of music to the player at once, usually when I rebuild the player from scracth the first time after migrating to a new hard drive capacity.

This is a player / sync bug, not a hijack bug.

During the sync, there appears to be a fixed maximum for the number of playlists (not fids, not tunes) that can be sent to the player at any time. It is almost as if there is a fixed memory space allocation for the number of playlists that can be loaded during any one sync session. The only way I have gotten around it was to pre-upload the playlists in small batches. Once the playlists were there, I could upload over 100GB of music at a time.

The symptoms you see with this is that emplode will crash hard in the middle of the sync while uploading a playlist, and the empeg will lock up. I do not remember any hijack or kernel errors on the player, but it was a while since I did this.