Ok: what I'd suggest is using Disk Utility to erase and zero the external drive: both the data and free space. I think you really are getting I/O errors on the drive, and this is the best way to at least remap any bad sectors.
I know that things were working in DU, but that copies entirely differently. The errors are being returned from the kernel, though, so I really do think they're real errors!
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--Dave Nanian
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