Cannot copy files to/from external drive

Hi All,
  Bit of a cry for help.  I run an iMac 3.06 Ghz Intel Core 2 Duo with 10.7.3 and I'm having some serious problems with an external drive.  Some history first - I have a large iTunes library (~3Tb) of everytype of media which I stored on an external NAS (iomega StorCenter) with no problems - then this NAS started to report a drive error with imminent failure.  I purchased a new DAS (Western Digital) drive and moved all my content from the NAS to the DAS and everything was ok.  Then I started to get errors through iTunes about cannot find the file and cannot read the files - and then I couldn't access anything on the drive.  At this time I thought this was a different problem because I was running preview Mountain Lion, or there was an actual fault with the disk.  After investigation, and coughing out for Data Rescue 3 I found that somehow the entire file structure had been corrupted and all my files had been orphaned.  So at this point I had one dying NAS drive and one DAS which wasn't usable and no space to recover any files to.
  So - next step was to purchase another external drive (and returned the WD) - this time I went for a G-Raid 4Tb (non-thunderbolt) drive and I've been in the process of recovering files from backups and iTunes.  I've had no problems until today when yet again I've started getting errors and now I have problems copying files to/from this G-Raid drive.
  Technical details - OS-X 10.7.3 - G-Raid 4Tb formatted as Mac OS Extended (Journaled) - currently showing 1,163 folders and 15,452 files.
  Symptoms - using finder drag and drop copy a file from the g-Raid to desktop results in 'The operation can't be completed because the item 'xxx' is in use. - 'The operation can't be completed because one or more required items can't be found (error code -43).' and the copy fails.
  Using the cp command I get a 'Resource Busy' error.
  However, this is not for all files - I've managed to copy all my books back to the desktop ok, when a couple came up with the above error I tried again and it copied successfully.
  I have run Disk Utility - here are the details :-
- 4TB G-Tech - Verify
Verifying partition map for “G-TECH”
Checking prerequisites
Checking the partition list
Checking for an EFI system partition
Checking the EFI system partition’s size
Checking the EFI system partition’s file system
Checking all HFS data partition loader spaces
Checking Core Storage Physical Volume partitions
The partition map appears to be OK
  Volume (Media) - Verify
Verifying volume “Media”
Checking file systemPerforming live verification.
Checking Journaled HFS Plus volume.
Checking extents overflow file.
Checking catalog file.
Unused node is not erased (node = 24190)
Checking multi-linked files.
Checking catalog hierarchy.
Checking extended attributes file.
Unused node is not erased (node = 24784)
Checking volume bitmap.
Volume bitmap needs minor repair for under-allocation
Checking volume information.
The volume Media was found corrupt and needs to be repaired.
Error: This disk needs to be repaired. Click Repair Disk.
Verify and Repair volume “Media”
Volume repair complete.Updating boot support partitions for the volume as required.Error: Couldn’t unmount disk.
Verify and Repair volume “Media”
Volume repair complete.Updating boot support partitions for the volume as required.Error: Couldn’t unmount disk.
Verify and Repair volume “Media”
Volume repair complete.Updating boot support partitions for the volume as required.Error: Couldn’t unmount disk.
Verify and Repair volume “Media”
Checking file systemChecking Journaled HFS Plus volume.
Checking extents overflow file.
Unused node is not erased (node = 94)
Checking catalog file.
Invalid sibling link
Rebuilding catalog B-tree.
The volume Media could not be repaired.
Volume repair complete.Updating boot support partitions for the volume as required.Error: Disk Utility can’t repair this disk. Back up as many of your files as possible, reformat the disk, and restore your backed-up files.
  and it's just got worse - in getting the info for this post I no longer have access to the drive.
  This is the second time this has now happened on two different directly connected drives (USB and Firewire) - which means the problem is elswhere.  I've a stack of errors in the system.log file
May 10 17:52:16 Neil-Cattons-iMac com.apple.diskmanagementd[1057]: ** /dev/disk1s1
May 10 17:52:16 Neil-Cattons-iMac com.apple.diskmanagementd[1057]: ** Phase 1 - Preparing FAT
May 10 17:52:16 Neil-Cattons-iMac com.apple.diskmanagementd[1057]: ** Phase 2 - Checking Directories
May 10 17:52:16 Neil-Cattons-iMac com.apple.diskmanagementd[1057]: ** Phase 3 - Checking for Orphan Clusters
May 10 17:52:16 Neil-Cattons-iMac com.apple.diskmanagementd[1057]: 0 files, 201632 KiB free (403265 clusters)
May 10 17:52:38 Neil-Cattons-iMac com.apple.usbmuxd[29]: _SendAttachNotification (thread 0x7fff799da960): sending attach for device fc:25:3f:7e:2a:19@fe80::fe25:3fff:fe7e:2a19._apple-mobdev._tcp.local.: _GetAddrInfoReplyReceivedCallback matched.
May 10 17:52:38 Neil-Cattons-iMac usbmuxd[29]: _AMDeviceConnectByAddressAndPort (thread 0x100781000): IPv4
May 10 17:52:39 Neil-Cattons-iMac iTunes[747]: _AMDDeviceAttachedCallbackv3 (thread 0x1180fc000): Device 'AMDevice 0x7ffe6d2d04a0 {UDID = f398e56f8aa95276585e0c5f74544bc24dda99bd, device ID = 58, FullServiceName = fc:25:3f:7e:2a:19@fe80::fe25:3fff:fe7e:2a19._apple-mobdev._tcp.local.}' attached.
May 10 17:52:40 Neil-Cattons-iMac fseventsd[15]: disk logger: failed to open output file /Volumes/Media/.fseventsd/fc007480d049964a (Invalid argument). mount point /Volumes/Media/.fseventsd
May 10 17:52:46: --- last message repeated 1 time ---
May 10 17:52:46 Neil-Cattons-iMac com.apple.usbmuxd[29]: _SendDetachNotification (thread 0x7fff799da960): sending detach for device fc:25:3f:7e:2a:19@fe80::fe25:3fff:fe7e:2a19._apple-mobdev._tcp.local.: _BrowseReplyReceivedCallback got bonjour removal.
May 10 17:52:46 Neil-Cattons-iMac iTunes[747]: _AMDDeviceDetached (thread 0x1180fc000): Device 'AMDevice 0x7ffe6d2d04a0 {UDID = f398e56f8aa95276585e0c5f74544bc24dda99bd, device ID = 58, FullServiceName = fc:25:3f:7e:2a:19@fe80::fe25:3fff:fe7e:2a19._apple-mobdev._tcp.local.}' detached.
May 10 17:53:40 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in _copyFile:error (2) opening 0.directoryStoreFile
May 10 17:53:40 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in recoverIndex:Unrecoverable error: could not recover path index (0.)
May 10 17:53:40 Neil-Cattons-iMac mds[39]: (Normal) DiskStore: Rebuilding index for /Volumes/Media
May 10 17:53:40 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in CIMetaInfoCreate:Tried to create index when index already existed
May 10 17:53:49 Neil-Cattons-iMac fseventsd[15]: disk logger: failed to open output file /Volumes/Media/.fseventsd/fc007480d049964a (Invalid argument). mount point /Volumes/Media/.fseventsd
May 10 17:54:01: --- last message repeated 1 time ---
May 10 17:54:01 Neil-Cattons-iMac login[1000]: DEAD_PROCESS: 1000 ttys000
May 10 17:54:05 Neil-Cattons-iMac fseventsd[15]: disk logger: failed to open output file /Volumes/Media/.fseventsd/fc007480d049964a (Invalid argument). mount point /Volumes/Media/.fseventsd
May 10 17:54:35: --- last message repeated 3 times ---
May 10 17:54:38 Neil-Cattons-iMac com.apple.usbmuxd[29]: _SendAttachNotification (thread 0x7fff799da960): sending attach for device fc:25:3f:7e:2a:19@fe80::fe25:3fff:fe7e:2a19._apple-mobdev._tcp.local.: _GetAddrInfoReplyReceivedCallback matched.
May 10 17:54:38 Neil-Cattons-iMac usbmuxd[29]: _AMDeviceConnectByAddressAndPort (thread 0x100781000): IPv4
May 10 17:54:46 Neil-Cattons-iMac fseventsd[15]: disk logger: failed to open output file /Volumes/Media/.fseventsd/fc007480d049964a (Invalid argument). mount point /Volumes/Media/.fseventsd
May 10 17:54:50: --- last message repeated 3 times ---
May 10 17:54:50 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in _copyFile:error (2) opening 0.directoryStoreFile
May 10 17:54:50 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in recoverIndex:Unrecoverable error: could not recover path index (0.)
May 10 17:54:50 Neil-Cattons-iMac mds[39]: (Normal) DiskStore: Rebuilding index for /Volumes/Media
May 10 17:54:50 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in CIMetaInfoCreate:Tried to create index when index already existed
May 10 17:54:51 Neil-Cattons-iMac fseventsd[15]: disk logger: failed to open output file /Volumes/Media/.fseventsd/fc007480d049964a (Invalid argument). mount point /Volumes/Media/.fseventsd
May 10 17:54:55: --- last message repeated 5 times ---
May 10 17:54:55 Neil-Cattons-iMac Finder[147]: ISGetIconFamilyFromStorage: seed mismatch for 238d0016, actual seed is 7fdcc233
May 10 17:54:55 Neil-Cattons-iMac Finder[147]: ISGetIconFamilyFromStorage: seed mismatch for 2f760017, actual seed is 1befd79f
May 10 17:54:55 Neil-Cattons-iMac Finder[147]: ISGetIconFamilyFromStorage: seed mismatch for 255a0018, actual seed is 41a7c4c9
May 10 17:54:55 Neil-Cattons-iMac Finder[147]: ISGetIconFamilyFromStorage: seed mismatch for 292e0019, actual seed is 6b68079a
May 10 17:54:55 Neil-Cattons-iMac Finder[147]: ISGetIconFamilyFromStorage: seed mismatch for 2263001a, actual seed is 4e6afb66
May 10 17:55:01 Neil-Cattons-iMac kernel[0]:
May 10 17:52:16 Neil-Cattons-iMac com.apple.diskmanagementd[1057]: ** /dev/disk1s1
May 10 17:52:16 Neil-Cattons-iMac com.apple.diskmanagementd[1057]: ** Phase 1 - Preparing FAT
May 10 17:52:16 Neil-Cattons-iMac com.apple.diskmanagementd[1057]: ** Phase 2 - Checking Directories
May 10 17:52:16 Neil-Cattons-iMac com.apple.diskmanagementd[1057]: ** Phase 3 - Checking for Orphan Clusters
May 10 17:52:16 Neil-Cattons-iMac com.apple.diskmanagementd[1057]: 0 files, 201632 KiB free (403265 clusters)
May 10 17:52:38 Neil-Cattons-iMac com.apple.usbmuxd[29]: _SendAttachNotification (thread 0x7fff799da960): sending attach for device fc:25:3f:7e:2a:19@fe80::fe25:3fff:fe7e:2a19._apple-mobdev._tcp.local.: _GetAddrInfoReplyReceivedCallback matched.
May 10 17:52:38 Neil-Cattons-iMac usbmuxd[29]: _AMDeviceConnectByAddressAndPort (thread 0x100781000): IPv4
May 10 17:52:39 Neil-Cattons-iMac iTunes[747]: _AMDDeviceAttachedCallbackv3 (thread 0x1180fc000): Device 'AMDevice 0x7ffe6d2d04a0 {UDID = f398e56f8aa95276585e0c5f74544bc24dda99bd, device ID = 58, FullServiceName = fc:25:3f:7e:2a:19@fe80::fe25:3fff:fe7e:2a19._apple-mobdev._tcp.local.}' attached.
May 10 17:52:40 Neil-Cattons-iMac fseventsd[15]: disk logger: failed to open output file /Volumes/Media/.fseventsd/fc007480d049964a (Invalid argument). mount point /Volumes/Media/.fseventsd
May 10 17:52:46: --- last message repeated 1 time ---
May 10 17:52:46 Neil-Cattons-iMac com.apple.usbmuxd[29]: _SendDetachNotification (thread 0x7fff799da960): sending detach for device fc:25:3f:7e:2a:19@fe80::fe25:3fff:fe7e:2a19._apple-mobdev._tcp.local.: _BrowseReplyReceivedCallback got bonjour removal.
May 10 17:52:46 Neil-Cattons-iMac iTunes[747]: _AMDDeviceDetached (thread 0x1180fc000): Device 'AMDevice 0x7ffe6d2d04a0 {UDID = f398e56f8aa95276585e0c5f74544bc24dda99bd, device ID = 58, FullServiceName = fc:25:3f:7e:2a:19@fe80::fe25:3fff:fe7e:2a19._apple-mobdev._tcp.local.}' detached.
May 10 17:53:40 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in _copyFile:error (2) opening 0.directoryStoreFile
May 10 17:53:40 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in recoverIndex:Unrecoverable error: could not recover path index (0.)
May 10 17:53:40 Neil-Cattons-iMac mds[39]: (Normal) DiskStore: Rebuilding index for /Volumes/Media
May 10 17:53:40 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in CIMetaInfoCreate:Tried to create index when index already existed
May 10 17:53:49 Neil-Cattons-iMac fseventsd[15]: disk logger: failed to open output file /Volumes/Media/.fseventsd/fc007480d049964a (Invalid argument). mount point /Volumes/Media/.fseventsd
May 10 17:54:01: --- last message repeated 1 time ---
May 10 17:54:01 Neil-Cattons-iMac login[1000]: DEAD_PROCESS: 1000 ttys000
May 10 17:54:05 Neil-Cattons-iMac fseventsd[15]: disk logger: failed to open output file /Volumes/Media/.fseventsd/fc007480d049964a (Invalid argument). mount point /Volumes/Media/.fseventsd
May 10 17:54:35: --- last message repeated 3 times ---
May 10 17:54:38 Neil-Cattons-iMac com.apple.usbmuxd[29]: _SendAttachNotification (thread 0x7fff799da960): sending attach for device fc:25:3f:7e:2a:19@fe80::fe25:3fff:fe7e:2a19._apple-mobdev._tcp.local.: _GetAddrInfoReplyReceivedCallback matched.
May 10 17:54:38 Neil-Cattons-iMac usbmuxd[29]: _AMDeviceConnectByAddressAndPort (thread 0x100781000): IPv4
May 10 17:54:46 Neil-Cattons-iMac fseventsd[15]: disk logger: failed to open output file /Volumes/Media/.fseventsd/fc007480d049964a (Invalid argument). mount point /Volumes/Media/.fseventsd
May 10 17:54:50: --- last message repeated 3 times ---
May 10 17:54:50 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in _copyFile:error (2) opening 0.directoryStoreFile
May 10 17:54:50 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in recoverIndex:Unrecoverable error: could not recover path index (0.)
May 10 17:54:50 Neil-Cattons-iMac mds[39]: (Normal) DiskStore: Rebuilding index for /Volumes/Media
May 10 17:54:50 Neil-Cattons-iMac mds[39]: (/Volumes/Media/.Spotlight-V100/Store-V2/5E86681D-E756-465C-925C-A631D78C3A46)( Error) IndexCI in CIMetaInfoCreate:Tried to create index when index already existed
May 10 17:54:51 Neil-Cattons-iMac fseventsd[15]: disk logger: failed to open output file /Volumes/Media/.fseventsd/fc007480d049964a (Invalid argument). mount point /Volumes/Media/.fseventsd
May 10 17:54:55: --- last message repeated 5 times ---
May 10 17:54:55 Neil-Cattons-iMac Finder[147]: ISGetIconFamilyFromStorage: seed mismatch for 238d0016, actual seed is 7fdcc233
May 10 17:54:55 Neil-Cattons-iMac Finder[147]: ISGetIconFamilyFromStorage: seed mismatch for 2f760017, actual seed is 1befd79f
May 10 17:54:55 Neil-Cattons-iMac Finder[147]: ISGetIconFamilyFromStorage: seed mismatch for 255a0018, actual seed is 41a7c4c9
May 10 17:54:55 Neil-Cattons-iMac Finder[147]: ISGetIconFamilyFromStorage: seed mismatch for 292e0019, actual seed is 6b68079a
May 10 17:54:55 Neil-Cattons-iMac Finder[147]: ISGetIconFamilyFromStorage: seed mismatch for 2263001a, actual seed is 4e6afb66
May 10 17:55:01 Neil-Cattons-iMac kernel[0]:
  I'm now out of ideas and when I got in touch with G-Tech support I got "Unfortunately the drive seems to have been corrupted. You can try to retrieve the data using third party data recovery software such as Data Rescue 3. You can find the software at a discounted rate at the following page:http://www.thedatarescuecenter.com/gtech-data-recovery-software.html  If you have any further questions, please feel free to ask."
  any help/advice/pointers very much appreciated as I really don't want to have to start recovering again :-(
Thanks all.

Hi Ncat,
I might have had similar problems with yours. Finder stuck at 'Not Responding' while I boot my Macbook Pro with external HDD plugged in, my macbook heats up considerably maybe because it keeps trying to access the external disk. And Finder can only proceed after I unplugged my external hard disk.
So what I did was:
I rebooted my macbook into recovery mode (by holding cmd+R before / during the booting chime
I used the Disk Utility from there (instead of from normal booting)
Then I proceed to with 'Repair Permissions' and 'Repair Disk' for each and every partition of the external harddisk, and also my internal hard disk.
Rebooted after everything's done, and now it seems to work.
I hope that it will work for you

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