1. When we go live, it will be around 150.
2. Almost all will be making changes. Only a few will be restricted to running reports, examine, ect..
3. The primary live backend is Red Hat ES 4.0 while the mirror is located offsite running Windows 2000 server.
4. Yes, we can be pretty flexible with this.
I'm running a demo of a product called Filereplicationpro
http://www.filereplicationpro.com/ . It will run on any OS that supports Java 1.4.1 which makes it perfect for replicating between Linux and Windows. My first tests have revealed that it works pretty well on its own. I currently have it configured to do byte level replication as changes are detected on the primary server. I simulated a disaster by dropping the network connection on the primary Red Hat server. I connected to the mirrored server at the other location and started the Sesame server using the replicated database. I was able to pull up new records I created just before I pulled the plug. However, during a few tests, I received an error indicating that the database could not be opened. After trying to unlock, the database would load to about 99% and then give me a similar error. Looking at the logs, I would then see info about records missing. I was never able to open it. My goal is make sure this never happens in a real disaster situation.
I'm not the developer of the application but a systems engineer trying to implement it. Please forgive me for my lack of Sesame lingo. Your saying that its possible for the Sesame file set to be copied during live operations? What exactly is the "Sunlock" process, or did you mean unlock process?

Is this the administrative tool that gives you the locked or unlocked status and allows you to unlock databases?
Putting the Sesame process in suspend mode sounds interesting. With my current user load, (which will be growing) how fast must I perform this so that users don't see or have any problems? Is this even possible to do this with so many people writing to the database at once? What will happen while someone is trying to save a record during this process?
I'll begin looking into this as it seems to be the best solution. Thanks for all your help on this. Test.. test.. test..