A very vague note on the SL size issue...
 
Previous powerpatches had this problem.  Within segmenter, several of the
SL manipulation commands (cleansl? copysl?) involve specifying the result
file being a "percentage of the current EOF".  Apparently it was deleting
out old segments, cleaning it up reserving some room, then adding back
the new ones and doing octcomp.  Some ran out of space.
 
This has been mentioned before, somewhere, in a document far, far away...
 
This is the first I've heard of it with express 3 though, so caveat emptor.
 
Jeff Kell <[log in to unmask]>