External Disk Problems - Serious

Dear Apple,
10.4.3, eMac latest, 512MB.
external USB2 drive, freshly formatted, extended non-journaled
Problem. Doing anything with the disk Finder-wise (like getting info on large folder) while copying something large (32Gb folder) to the external disk hangs the finder for good. This is 100% reproducible behavior. I assume this has something to do with Apple's USB driver or Finder.
PLEASE FIX IT BEFORE WE SUE YOU.

Thaks for suggestions. Here is what I know:
a) disk is external 160Gb, formated with Apple utilities, extended HFS+ single partition.
b) the disk is mass produced, sold by Frys, manufacturer claims they never heard of this, their suggestions (go single port not ext hub, bad port, bad cable) did not pan out. They are 100% the problem isn't theirs.
c) there is no trace of anything in any log except when I pull the plug on that drive.
d) there is no report of anything similar on the web.
e) again the problem is, in the middle of file copy the transfer stops, the drive indicates (light) that is stuck writing. After some 10 sec the drive goes back to normal mode and the system loses ability to communicate with the drive. Finder hangs. That happens with 100% reproducibility but at very variable point in transfer (1M to 1G). Puling the USB cable immediately un-hangs the Finder.
f) I did try using cp, same problem, also running from safe boot mode (extension disabled), no difference.
Short of buying another drive and computer to try to mail the culprit I see nothing else to try except blaming Apple simply because I agree external USB silicon is extremely unlikely to have a problem synching communications with the mac.
  Mac OS X (10.4.2)  

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