On Wed, 2010-01-20 at 10:33 +0000, Stuart Rowan wrote:
> >>>> dovecot: 2009-07-28 10:23:16 Error: IMAP(strr): Corrupted index cache 
> >>>> file /home/local/strr/Maildir/dovecot.index.cache: record continues 
> >>>> outside its allocated size
> >>>> dovecot: 2009-07-28 10:23:56 Error: IMAP(strr): Corrupted index cache 
> >>>> file /home/local/strr/Maildir/dovecot.index.cache: record continues 
> >>>> outside its allocated size
> > ..
> > What filesystem are you using? NFS or any other remote filesystem?
> XFS as a local filesystem.

Weird. See what it logs with the attached patch?

diff -r a1177c6cf8c7 src/lib-index/mail-cache-lookup.c
--- a/src/lib-index/mail-cache-lookup.c	Wed Jan 20 11:44:06 2010 +0200
+++ b/src/lib-index/mail-cache-lookup.c	Wed Jan 20 15:35:00 2010 +0200
@@ -263,7 +263,8 @@
 
 	if (ctx->rec->size - ctx->pos < data_size) {
 		mail_cache_set_corrupted(cache,
-			"record continues outside its allocated size");
+			"record continues outside its allocated size %u-%u<%u, field=%s",
+			ctx->rec->size, ctx->pos, data_size, cache->fields[field_idx].field.name);
 		return -1;
 	}
 

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