I have a strange problem on Linux 2.4.9-e.35enterprise with one of the filesystems. Although it is empty it is reporting 100% Inodes

df -k reports
/dev/sdb3 10239456 34912 10204544 1% /BEX101-archive

where as df -i reports:
/dev/sdb3 79996 79723 273 100% /BEX101-archive

Log files go into that directory and are deleted every hour - so it is always empty

Any ideas?

This means that there are 79723 files, directories and links on the filesystem and only 273 more can be created. You have 1 inode per 128kB which means your filesystem is setup for an average filesize of 128kB. However, you average filesize is ~2.3kB so you run out of inodes way before you run out of free space.

Since the number of inodes cannot be increased on the fly (on an ext3 filesystem, anyway which I believe is what RHEL uses) you will have to recreate the filesystem. And this time you should use something like 2048 bytes/inode.

edit: err actually, I got the numbers wrong: your avg filesize is even smaller: ~0.5kB/file. Since the smallest blocksize for ext3 is 1024 bytes and it's useless to have more inodes than blocks you should use a blocksize of 1024B and also 1024B/inode