Sam,
What about manually trying to create the aliases file. What procedure
would I follow, to help locate where the problem lies.
I would suggest the following troubleshooting process:
Take everything in the aliases directory, and move them elsewhere. You should now have a completely empty aliases directory.
Run makealiases. Make sure it succesfully generates an empty alias database.
Begin putting back one file at a time, into the aliases directory, running makealiases each time.
Sooner or later you'll figure out what the problem is.
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