Hi Ken - I had to drop this last year as the problem went away when I moved to a production server. However, it's back again and this time I had a chance to try out the test you have below. I am able to go up to 83 connections and after that I get a SystemStackError:
➜ ~/Downloads $ ruby max.rb 83
Tested 83 connections.
Process IDs: [56, 58, 59, 60, 61, 62, 63, 64, 65, 66, 68, 69, 70, 71, 72, 73, 74, 75, 76, 77, 78, 79, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 102, 103, 104, 105, 106, 107, 108, 109, 110, 111, 112, 113, 114, 115, 116, 117, 118, 119, 120, 121, 122, 123, 124, 125, 126, 127, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140]
➜ ~/Downloads $ ruby max.rb 84
/opt/ruby/lib/ruby/gems/1.9.1/gems/tiny_tds-0.6.0.rc1/lib/tiny_tds/client.rb:70: stack level too deep (SystemStackError)
I tried with the 0.5.1 version and also the 0.6.0rc1 version and same result. Any ideas on where I'd go from here? I'm on a Mac OS X 10.8.3 with ruby 1.9.3p0 (2011-10-30 revision 33570) [x86_64-darwin11.2.0]. Thanks!