I currently have a problem that others have had before, but no one actually did anything to explain or help.

I have a mail server that is often under high load. It panics about every day or two with "vm_thread_new: kstack allocation failed". I have a dump, but I doubt it is necessary as the details of this problem have been documented many times before.

threads/80435: panic on high loads
http://lists.freebsd.org/pipermail/freebsd-threads/2005-April/ 003025.html
No resolution because reporter wasn't running -STABLE.

panic: vm_thread_new: kstack allocation failed
http://lists.freebsd.org/pipermail/freebsd-current/2006-March/ 061544.html
No discussion about it other than testing methods.

FreeBSD 5.4-P12 Panic "vm_thread_new: kstack allocation failed" under load http://lists.freebsd.org/pipermail/freebsd-questions/2006-March/ 116290.html
Just a "pass the buck" comment about upgrading to 6.1

I *am* running 6-STABLE. I have had this particular panic since 5.4- RELEASE. I am using an SMP kernel with only this change to fix a different kernel panic before.
  options VM_KMEM_SIZE_MAX=419430400
The machine is a dual AMD Opteron w/ 2G memory. I have another identical machine that this also occurs on but less frequently as it does not have as high of a load. I have tested every piece of hardware as best as I can, especially the memory.

I have been fighting this issue for months now. I am about to give up and go back to FreeBSD 4.x. I am looking for suggestions now.

1. What does this panic really mean?
2. Any ideas for a work around?  (kernel options, patches, anything)
3. Would a bug report actually get anywhere? (bad experiences in the past, 93809)

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