Yep, tried disabling Hyper threading and got the same problems. I think the
error is more to-do with the compile tool itself rather than a
hardware/software configuration on my end.

I tried compiling with the -verbose switch and got the following output:
------------------------------------------------------------------------------------------------------------
D:\MOD_TEST\src\materialsystem\stdshaders>buildsdkshaders.bat
Setting environment for using Microsoft Visual Studio 2010 x86 tools.
12:56

12:56
Building inc files, asm vcs files, and VMPI worklist for newShaders...
Publishing shader inc files to target...
Generating action list...
Running distributed shader compilation...
After VMPI_Init
After VMPI_FileSystem_Init
After Shared_ParseListOfCompileCommands
getting local copy of shader: "..\..\dx9sdk\utilities\dx_proxy.dll "
("D:\MOD_TEST\src\materialsystem\stdshaders\..\..\dx9sdk\utilities\dx_proxy.dll
")
creating "C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\dx_proxy.dll "
getting local copy of shader: "SDK_lightmappedgeneric_ps2x.fxc"
("D:\MOD_TEST\src\materialsystem\stdshaders\SDK_lightmappedgeneric_ps2x.fxc")
creating
"C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\SDK_lightmappedgeneric_ps2x.fxc"
getting local copy of shader: "SDK_lightmappedgeneric_vs20.fxc"
("D:\MOD_TEST\src\materialsystem\stdshaders\SDK_lightmappedgeneric_vs20.fxc")
creating
"C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\SDK_lightmappedgeneric_vs20.fxc"
getting local copy of shader: "common_flashlight_fxc.h"
("D:\MOD_TEST\src\materialsystem\stdshaders\common_flashlight_fxc.h")
creating
"C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\common_flashlight_fxc.h"
getting local copy of shader: "common_fxc.h"
("D:\MOD_TEST\src\materialsystem\stdshaders\common_fxc.h")
creating "C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\common_fxc.h"
getting local copy of shader: "common_hlsl_cpp_consts.h"
("D:\MOD_TEST\src\materialsystem\stdshaders\common_hlsl_cpp_consts.h")
creating
"C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\common_hlsl_cpp_consts.h"
getting local copy of shader: "common_lightmappedgeneric_fxc.h"
("D:\MOD_TESTmoon_Reborn\src\materialsystem\stdshaders\common_lightmappedgeneric_fxc.h")
creating
"C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\common_lightmappedgeneric_fxc.h"
getting local copy of shader: "common_pragmas.h"
("D:\MOD_TEST\src\materialsystem\stdshaders\common_pragmas.h")
creating
"C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\common_pragmas.h"
getting local copy of shader: "common_ps_fxc.h"
("D:\MOD_TEST\src\materialsystem\stdshaders\common_ps_fxc.h")
creating
"C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\common_ps_fxc.h"
getting local copy of shader: "common_vs_fxc.h"
("D:\MOD_TEST\src\materialsystem\stdshaders\common_vs_fxc.h")
creating
"C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\common_vs_fxc.h"
getting local copy of shader: "lightmappedgeneric_ps2_3_x.h"
("D:\MOD_TESTmoon_Reborn\src\materialsystem\stdshaders\lightmappedgeneric_ps2_3_x.h")
creating
"C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\lightmappedgeneric_ps2_3_x.h"
getting local copy of shader: "shadercompile.exe "
("D:\MOD_TEST\src\materialsystem\stdshaders\shadercompile.exe ")
creating
"C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\shadercompile.exe "

getting local copy of shader: "shadercompile_dll.dll "
("D:\MOD_TEST\src\materialsystem\stdshaders\shadercompile_dll.dll ")
creating
"C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\shadercompile_dll.dll "
getting local copy of shader: "tier0.dll "
("D:\MOD_TEST\src\materialsystem\stdshaders\tier0.dll ")
creating "C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\tier0.dll "
getting local copy of shader: "vstdlib.dll "
("D:\MOD_TEST\src\materialsystem\stdshaders\vstdlib.dll ")
creating "C:\Users\Alex\AppData\Local\Temp\shadercompiletemp\vstdlib.dll "
trying to open: .\\mysql_wrapper.dll
trying to open: .\\vstdlib.dll
trying to open: .\\tier0.dll
Compiling 2,717,911,040 commands in 18,874,624 static combos.
0 File(s) copiedightmappedgeneric_ps20b  [ 7864327 remaining ] ...
13:21

D:\MOD_TEST\src\materialsystem\stdshaders>
-------------------------------------------------------------------------------------------------
It all looks OK and then bombs out all of a sudden.

I wonder if VALVe would be so kind as to give us a copy of ShaderCompile.exe
(and its associates) as a hotfix so we can actually compile the larger
shaders without having to suffer 4/5 hour compile times.
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