Hi Paul,
r865 works for me. Just thought I'd let you know.
All of the pink lines of death around where I work have now disappeared.
That's great.
As suggested below I have set $rnod to 30 in osm2mp.pl
I have now determined the max number of nodes in a way that I can have before a particular route on a particular map goes wrong on an etrex vista. The max number is 18. So, while 30 may work in other situations, it won't work for all maps/routes/gps's. I don't believe there is a huge cost in space/speed if you break a way into segments that have fewer routing nodes. After all, a large proportion of the roads in the map will only have a few routing nodes anyway, so partitioning a relatively small number of roads into segments should have little impact on resource usage. Cheers, Mark