As an update I have managed to build a debug kernel and look at the cores. Nothing spectacular it looks pretty random to me. Today I got a core dump as well....and I'm not running gmirror! So the problem is more fundamental. I have done some tests and seems fairly random...as if there is a random memory or meta-data problem.
I was running the disks in dedicated mode? Where my mount is something like /dev/ad4 instead of /dev/ad4s1d. the BSDLabel looked pretty funny to me.
two partitions, one large one at a small offset and then a large one at 0. which looked suspicious-probably a left over from gmirror label?
So I've now gone into sysinstall and fdisk and label options and redone the disks. Will have to see how that runs. I've still got to finish it off tomorrow...
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