Duff Man wrote:
Thanks for your thoughts, they seem reasonable, but again I think it's been tried.
What I suggested is a focus for investigation from this point onwards, so you can't have tried that investigation already

(unless you already have the file throughput benchmark results for comparison?).
Duff Man wrote:
A file that will not play on the WD drive, is then copied to an IDENTICAL WD and bam, works.
or that same file is copied to any other drive and it works.
OK, that wasn't completely clear to me in your post before, but I see it now. That's great, in fact - identical disks, one "works" & one "fails". Focussing just on those 2 disks - identify every difference, and compare everything about them and the way they are being used at the time of "the problem" (ignoring, for the moment, the other disks).
As I noted before, that comparison does NOT just mean focussing on the hardware. The disks will have different drive letters, so from an OS point of view, they are
not identical e.g. you can have different settings (like background indexing etc. etc.) set for different drive letters. What other data can you get out of VLC - any logging?
Duff Man wrote:
I understand the data throughput idea (I think) but it's compared against 2 of the same, and they have no problem.
As I said, there are elements of your system which are not identical, even between 2 disks of the same model (e.g. filesystem layout, OS settings etc.). Doing the file benchmarking is something I would be doing to start with.
Duff Man wrote:
Oh and VLC is the program that can't run the file (while it runs identical copies) but under OSX running VLC everything is fine.
Understood - but unless you can find a reason why VLC isn't playing the file under Vista from that disk (i.e. an error message), then you don't know that VLC on OSX isn't just slightly more efficient (for example), or have different error handling, or just able to cope better with whatever the underlying issue is. Lack of a visible problem on OSX does not mean that no problem is occurring - it could just be that OSX (or the VLC compilation for OSX) is handling it differently.
Have you been looking in the Vista System & Application event logs for any clues? Have you investigated whatever VLC does for error logging?
Duff Man wrote:
FINALLY the bad drive can play 720p files, that are a larger filesize than some of the 1080p ones (of which none work)
Yes, I understood that from before - the size of the file has nothing to do with necessary file throughput. The data throughput which is needed, will depend on the file format. So your evidence here about other file formats playing OK, confirms a bottleneck in data throughput somewhere as the likely problem.

Since you have already replaced the "suspect" disk (and got the same results) and have another disk that "works OK", then I see no evidence that this is actually a disk hardware problem.
Since I'm remote from the problem, I doubt I'll be able to find your "smoking gun" - in my experience, it is much more efficient to have someone in front of the equipment who is familiar with this kind of troubleshooting. Good luck with whatever you decide to do
