I'm not sure about that FJ. I looks like cifs was designed to support large file sizes (>2GB). I'm not sure but people suggest using the "-o lfs" option when mounting the share. Bob2nd, could you try telnetting into the OSD &
manually mount your PC's network share there? Just to test it out?
If you try FJ's suggestion, make sure the external HDD is not FAT32, since it has a 2GB limit (as I'm sure you know). The OSD can write to ext2 & ext3 formatted drives.
I does sound like the >2GB file is being truncated, doesn't it? PC's are forgiving when playing such files. If you use VLC have a look at it's error messages as you play the >2GB file.
-G