Thanks for the info Paul, glad to see I'm not the only one experiencing this problem.
I'm a bit sceptical about installing SFS, I have it on my internet cache partition but I don't trust it with as my main file system yet. Although a lot of people seem to be giving it good reports.
I did manage to get the machine to stay up without guru'ing only by booting into the OS4 beta partition I have installed. Don't know what it does, but it stops it crashing.
I have since managed to salvage my data (all 18,000 files) and reformat the disk with FFS2 so I'll see how that goes. Maybe I will move to SFS if that fails.
I was just posting to see if anyone else had this problem, and what the actual guru code of 8000 0004 was, and how it was related to my validation process.
No salvage utility I have used successfully in the past (Disksalv, Quarterback, TurboVal) could repair the problem, as you say it needed a re-format. Nasty stuff.