I think I've managed to isolate the problem to the Adaptec 5405 RAID Controller.... we're going to throw in a SATA HDD tonight and bypass the controller, install proxmox and test.
The problem is not present on another platform (proxmox1.6 also) which is running a different RAID controller, and IS present on a third system running the same Adaptec controller...
Not looking good for the Adaptec 5405 + rsync!!
I will come back and confirm the above, or any other findings.