I replaced the cygwin1.dll with cygwin1-20110309.dll and now a single
write() with 78 MB never returns but seems to write repeatedly to the
pipe (file was 5GB when I hit Ctrl-C).

Just terminating the loop after write_overlapped_fallback is not enough.
When the size to write exceeds MAX_OVERLAPPED_WRITE_LEN and WriteFile fails for MAX_OVERLAPPED_WRITE_LEN, write() will always return 0.

In case of overlapped_error, nbytes should be set to -1.

I'd suggest to remove write_overlapped_fallback and instead decrement 'len' on each failure. Since write is not guaranteed to write the whole data, this should be OK.

      do
        {
          bool res = WriteFile (get_output_handle (), ptr, len, &nbytes,
                                get_overlapped ());
switch (wait_overlapped (res, true, &nbytes, is_nonblocking (), (size_t) len))
            {
            case overlapped_fallback:
                  len /= 4; /* feel free to tune */
                  if (!len) {
                    set_errno (ENOSPC); /* Can't write anything */
                    nbytes = (DWORD) -1; /* Don't forget */
                    keep_looping = false;
                    break;
                  }
              /* fall through intentionally */;
            case overlapped_signal:
              keep_looping = true;
              break;
            default:    /* Added to quiet gcc */
            case overlapped_error:
              nbytes = (DWORD) -1; /* Don't forget */
              /* fall through intentionally */;
            case overlapped_success:
              keep_looping = false;
              break;
            }
        }
      while (keep_looping);

Result (from the application's perspective) is:

writing 78954543 bytes...
result is 19738635, errno is 0
writing 59215908 bytes...
result is 14803977, errno is 0
writing 44411931 bytes...
result is 11102982, errno is 0
writing 33308949 bytes...
result is 8327237, errno is 0
writing 24981712 bytes...
result is 24981712, errno is 0

-Robert

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