Tape backup "Used Capacity" consistently higher than "Data"
Server 2003 (SBS) 32bit, using Backup Exec for Windows Servers (problem first seen in 11d, same problem exists in 2010 R2) with an LTO5 tape drive, LTO4 tape media.
Backups are consistently using significantly more space on the tape than the data written (eg a backup fills a blank LTO4 tape, 780Gb of 781.5Gb capacity, job hangs waiting for overwritable media to be inserted) with only 460Gb of data written to tape.
Have tried all combinations of hardware software compression - compression does appear to succesfully compress data (compression might get 580Gb of data on a 780Gb tape)
Diagnostic tools suggest the tape drive is OK, have tried latest vendor drivers and latest symantec supplied drivers. Have tried adjusting the selection list (exclude large portion of data, problem remains, exclude everything and include only what was previously excluded, still same issue).
The same amount of data was previously just at capacity on an LTO3 tape which achieved around 1.4:1 compression.
I've never seen anything like this before, and can't find anyone else with similar problems - will test with NTBackup and possibly LTO5 media, but I have no intention of using either of these for actual backups at this stage.
Damn, turns out it was actually a faulty tape drive. While diagnostics completed succesfully on LTO4 media and no errors were reported during backup, LTO5 media resulted in write failures, diagnostics failed, drive was replaced and all is well.

