XDCAM EX files unusual behavior

I'm 2 days into a 3 day 3 camera shoot using and EX-1, EX-3 and Varicam H model. Running tome of day time code with the EX-3 generating tc to the varicam. We're shooting long takes with at the end of the day ending up with 4 hours or so material from each camera.

As I transfer my files in the evening I'm seeing incomplete clip files (.SMI) like you would if the file spanned 2 cards. This is happening on the EX-3 and EX-1. In most cases the file is broken into 2 clips, but once in awhile there is a third clip in the file. This generally happens with the last 2 or 3 clips on the card. Using two 32gig cards and 4, 16 gig cards with some 8 gig cards if needed.

I put the clips on the timeline and they're seamless in the way the match up.

I'm also seeing some breakup in the EX-3 in the monitor, but not in the files. I have it going into a Panasonic 17" HD monitor via component with the EX-1 and Varicam going in HDSDI.

Anyone have a clue what's happening here. Everything looks great and it's working, but not the way I'd like nor the way it has in the past.

thx...jw