I believe I have found it - but to respond to the posts...
Post the code...
Are you sending to the serial output part of the string as long as you are putting it toghether or you are sending a big buffer all at once?
Mauro
The code isn't going to help you unless I post the whole lot (and even then, I have my doubts) - and I'm not doing that ... especially now.
The error that is 'star space box space box' repeats every four and a bit lines. How odd.
Accidental recursion (calling a function from within itself) perhaps?
Thank you for looking at the pattern - that's what I was hoping someone might recognise. You are forgiven for not having an answer, but you effort is appreciated.
My suspicion was that there may have been an issue with the serial output buffer getting corrupted.
The problem seems to have been alleviated by going through the sketch and commenting out a lot of the debugging code and variables. This was prompted by reviewing the compiler messages warning of low memory availability causing stability problems.
I had seen this message frequently and there had been no problems (until now) so I had not paid close attention to the details - but this time I check the figures and it reported that there was only 180 bytes free for local variables ... and that might not be enough.
I tend to run with Global variables - so I might need to look at a more intelligent use of Local variables if things get tight.
To test this theory out, I re-enabled a truckload of Serial and Serial.print statements - and it all ran smooth as silk.