OK now updated to latest and greatest:
mergerfs version: 2.28.1
FUSE library version: 2.9.7-mergerfs_2.28.0
fusermount version: 2.9.7
using FUSE kernel interface version 7.29
Gave it another shot but sadly same thing:
2019/06/12 15:24:05 INFO : cache: Cache DB path: /home/td001/.cache/rclone/cache-backend/cache.db
2019/06/12 15:24:05 INFO : cache: Cache chunk path: /home/td001/.cache/rclone/cache-backend/cache
2019/06/12 15:24:05 INFO : cache: Chunk Memory: true
2019/06/12 15:24:05 INFO : cache: Chunk Size: 64M
2019/06/12 15:24:05 INFO : cache: Chunk Total Size: 32G
2019/06/12 15:24:05 INFO : cache: Chunk Clean Interval: 1m0s
2019/06/12 15:24:05 INFO : cache: Workers: 4
2019/06/12 15:24:05 INFO : cache: File Age: 2d
2019/06/12 15:24:06 INFO : cache: Cache DB path: /home/td001/.cache/rclone/cache-backend/cache.db
2019/06/12 15:24:06 INFO : cache: Cache chunk path: /home/td001/.cache/rclone/cache-backend/cache
2019/06/12 15:24:06 INFO : cache: Chunk Memory: true
2019/06/12 15:24:06 INFO : cache: Chunk Size: 64M
2019/06/12 15:24:06 INFO : cache: Chunk Total Size: 32G
2019/06/12 15:24:06 INFO : cache: Chunk Clean Interval: 1m0s
2019/06/12 15:24:06 INFO : cache: Workers: 4
2019/06/12 15:24:06 INFO : cache: File Age: 2d
2019/06/12 15:27:40 INFO : cache: Connected to Plex server: http://192.168.1.119:32400
2019/06/12 15:28:23 ERROR : crypt/br4l7oppte4ln8ma74vj43u730/ef6eflke6h82ame2ue68k6tvuc/61c4f9nq4662m78pm5p6chknac/ul4th582g8bb18si1fr3c26f80inp9nn7ne4sjqprj4v5nqr7s5soctvfl1u3glqs0j87ev46k5sttgsr6qlmf6e3lnvpd1ukajtbt9hk7vgbvadoflsko4i55nn1655: (8316582272/8316683544) error (chunk not found 8254390272) response
2019/06/12 15:29:04 ERROR : crypt/br4l7oppte4ln8ma74vj43u730/ef6eflke6h82ame2ue68k6tvuc/61c4f9nq4662m78pm5p6chknac/ul4th582g8bb18si1fr3c26f80inp9nn7ne4sjqprj4v5nqr7s5soctvfl1u3glqs0j87ev46k5sttgsr6qlmf6e3lnvpd1ukajtbt9hk7vgbvadoflsko4i55nn1655: (8316582272/8316683544) error (chunk not found 8254390272) response
2019/06/12 15:29:28 ERROR : TV/Westworld/Season 2/Westworld.S02E01.Journey.Into.Night.1080p.UHD.BluRay.DTS.HDR.x265-LYS.mkv: ReadFileHandle.Read error: low level retry 1/10: EOF
2019/06/12 15:30:13 ERROR : crypt/gu429mg4onhpaq5g5jm100419o/1apbp8rm7m1jarpv5h7tbat8ta318s159nhu70a1u5u7o3fe1o8g/n7j6rcc63gu2v6n6ectu6id6kue8vgcpfpfptba27t6bctbfh32161gqi4lhf13nkvln7fn0dekq6: (67108864/8218062764) error (chunk not found 67108864) response
2019/06/12 15:30:13 ERROR : Movies/Detroit Rock City (1999)/Detroit Rock City (1999) Bluray-1080p.mkv: ReadFileHandle.Read error: low level retry 1/10: unexpected EOF
I should note though that despite the error messages, if I wait like 4 or 5 min the buffering ends and it continues to play. I mention this because the errors seem to indicate "missing chunks" but oddly movie doesn't skip or anything.
Something else to mention - hoping this might help... it appears that plex is scanning some new files and I've noticed some additional new error messages in the rclone.log:
2019/06/12 15:30:50 ERROR : crypt/br4l7oppte4ln8ma74vj43u730/ef6eflke6h82ame2ue68k6tvuc/61c4f9nq4662m78pm5p6chknac/n84p50qhg0hdectki5ivh1m3a78hvdndjc1guh4pgc0medp3g5t28tr9icf0974dj31llvdq1egca: (4829674736/4829749025) error (chunk not found 4764729344) response
2019/06/12 15:30:50 ERROR : crypt/br4l7oppte4ln8ma74vj43u730/ef6eflke6h82ame2ue68k6tvuc/61c4f9nq4662m78pm5p6chknac/n84p50qhg0hdectki5ivh1m3a78hvdndjc1guh4pgc0medp3g5t28tr9icf0974dj31llvdq1egca: unexpected conditions during reading. current position: 4829674736, current chunk position: 4764729344, current chunk size: 26800128, offset: 64945392, chunk size: 64M, file size: 4829749025
2019/06/12 15:30:50 ERROR : TV/Westworld/Season 2/Westworld.S02E02.1080p.WEB.H264-DEFLATE.mkv: ReadFileHandle.Read error: low level retry 1/10: unexpected EOF
2019/06/12 15:31:56 ERROR : crypt/br4l7oppte4ln8ma74vj43u730/ef6eflke6h82ame2ue68k6tvuc/61c4f9nq4662m78pm5p6chknac/uau7e4lm468d7j0sv0j6pvchrmg0ffdgimmq2ilknqrcmiqhnfsr07kc7sr25mpv5mqi3el7ut02td5psqpa38al5tk983l5eft2ltma2qupedfkpfufkk73jg1a5tp1: unexpected conditions during reading. current position: 1257615152, current chunk position: 1207959552, current chunk size: 3334144, offset: 49655600, chunk size: 64M, file size: 1257686781
2019/06/12 15:31:56 ERROR : crypt/br4l7oppte4ln8ma74vj43u730/ef6eflke6h82ame2ue68k6tvuc/61c4f9nq4662m78pm5p6chknac/uau7e4lm468d7j0sv0j6pvchrmg0ffdgimmq2ilknqrcmiqhnfsr07kc7sr25mpv5mqi3el7ut02td5psqpa38al5tk983l5eft2ltma2qupedfkpfufkk73jg1a5tp1: unexpected conditions during reading. current position: 1257615152, current chunk position: 1207959552, current chunk size: 9232384, offset: 49655600, chunk size: 64M, file size: 1257686781
2019/06/12 15:31:56 ERROR : TV/Westworld/Season 2/Westworld.S02E04.the.Riddle.of.The.Sphinx.1080p.AMZN.WEB-DL.6CH.MKVCAGE.COM.mkv: ReadFileHandle.Read error: low level retry 1/10: unexpected EOF
"unexpected conditions during reading. current position: 1257615152, current chunk position: 1207959552, current chunk size: 9232384, offset: 49655600, chunk size: 64M, file size: 1257686781" - don't think I've seen this message during my searches.