Quick update on my attempts:  Got the latest testing branch 0.89.99.6, and also boosted the ulimit on files to 4096 (from 1024).  This time I got much further in the database rebuild (to the 48th block file), but it eventually fell over with a "Bus Error" (OS error, not a Python Exception).  Trying to restart now without the --rebuild option and it seems to have continued from where it left off, so hopefully after a couple of attempts I'll get fully synced!

@etotheipi: Let me know if you want me to e-mail you any cores or logs?

Thanks.