The story so far for the 6TB HDD:
1. copy 4TB of files of backup
2. run Windows app (homebrew written in Delphi) to modify 6TB HDD file names and .nfo to reflect name changes
3. set up the RPi3s (LE 9.2.8, Kodi 18.9), removed sources and cleaned database
4. plugged 6TB HDD in
5. set up new sources and loaded database
6. no last played information
7. Exported database just in case nfo format was different
8. was told I'd forgotten about advanced settings.xml
9. use Windows via SAMBA to a) delete nfo files (c 7200 of them)
10. use Windwos via SAMBA to copy nfos from backup to 6TB HDD
11. removed sources, cleared databases, reset sources loaded database
12. everything fine
That pretty much confirms to me that the HDD is OK. I'm wondering if the incomplete implementation of SAMBA on the RPi4 could be responsible for the disk corruption. I can see no reason why Kodi should be writing to the sources unless I export the database and any file manipulation I do is via SAMBA so it will be writing to the disk.
Any thoughts?