I have a paper backup, so this is not a critical problem.
I generated around 10000 keys with a new wallet and sent money to a random selection of the addresses. I computed them with a separate program.
The transactions sent money to high numbered addresses with a large number of unused addresses in between.
Armory detected the incoming transactions, but I had to force generate lots of addresses.
I tried to send money from the wallet. After 10 minutes, Armory still hadn't unlocked it.
I killed the process and tried again. This time, I tried to create a paper wallet.
When I pressed unlock, it didn't lock-up the process, but it didn't give the paper wallet print screen.
I then restarted again to generate a clean log file.
This log file is when I tried to send a transaction. It doesn't seem to have anything in the log file.
I started Armory and then tried to send a transaction, once syncing was complete.
2013-08-09 23:16 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 2.9
2013-08-09 23:17 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 5.9
2013-08-09 23:17 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 8.8
2013-08-09 23:17 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 11.8
2013-08-09 23:17 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 14.7
2013-08-09 23:17 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 17.6
2013-08-09 23:17 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 20.6
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 23.5
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 26.5
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 29.4
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 32.4
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 35.3
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 38.2
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 41.2
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 44.1
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 47.1
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 50.0
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 52.9
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 55.9
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 58.8
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 61.8
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 64.7
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 67.6
2013-08-09 23:18 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 70.6
2013-08-09 23:19 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 73.5
2013-08-09 23:19 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 76.5
2013-08-09 23:19 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 79.4
2013-08-09 23:19 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 82.4
2013-08-09 23:19 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 85.3
2013-08-09 23:19 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 88.2
2013-08-09 23:19 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 91.2
2013-08-09 23:19 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 94.1
2013-08-09 23:19 (INFO) -- armoryengine.pyc:11880 - Reading blockchain, pct complete: 97.1
2013-08-09 23:19 (INFO) -- ArmoryQt.py:4166 - Dashboard switched to fully-online mode
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3541 - Switching Armory state text to Mgmt:User, State:OnlineFull1
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3483 - Switching Armory functional mode to "Online"
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3541 - Switching Armory state text to Mgmt:User, State:OnlineFull2
2013-08-09 23:19 (INFO) -- ArmoryQt.py:4166 - Dashboard switched to fully-online mode
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3541 - Switching Armory state text to Mgmt:User, State:OnlineFull1
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3483 - Switching Armory functional mode to "Online"
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3541 - Switching Armory state text to Mgmt:User, State:OnlineFull2
2013-08-09 23:19 (WARNING) -- ArmoryQt.py:1758 - Memory pool file was corrupt. Deleted. (no further action is needed)
2013-08-09 23:19 (INFO) -- ArmoryQt.py:1697 - Syncing wallet:
2013-08-09 23:19 (INFO) -- ArmoryQt.py:1697 - Syncing wallet:
2013-08-09 23:19 (INFO) -- ArmoryQt.py:1697 - Syncing wallet:
2013-08-09 23:19 (INFO) -- ArmoryQt.py:1697 - Syncing wallet:
2013-08-09 23:19 (INFO) -- ArmoryQt.py:1709 - Current block number: 251198
2013-08-09 23:19 (INFO) -- ArmoryQt.py:4166 - Dashboard switched to fully-online mode
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3541 - Switching Armory state text to Mgmt:User, State:OnlineFull1
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3483 - Switching Armory functional mode to "Online"
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3541 - Switching Armory state text to Mgmt:User, State:OnlineFull2
2013-08-09 23:19 (INFO) -- ArmoryQt.py:4166 - Dashboard switched to fully-online mode
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3541 - Switching Armory state text to Mgmt:User, State:OnlineFull1
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3483 - Switching Armory functional mode to "Online"
2013-08-09 23:19 (INFO) -- ArmoryQt.py:3541 - Switching Armory state text to Mgmt:User, State:OnlineFull2
2013-08-09 23:20 (INFO) -- qtdialogs.pyc:5700 - Change address behavior: NewAddr
Next, I restarted and tried to print a paper backup. Doubling clicking on the wallet took a while (I assume to generate all the addresses). This time, when I tried to generate the paper backup, the process locked up.
Is it possible that it simply takes ages to unlock, even if you have the right passphrase? It was able to tell I had the wrong passphrase very quickly, when I tested it.
Something I noticed is that all wallet files appear to be updated when you start Armory. This means that the wallet file is potentially corrupted on every start.
An alternative system would be to have a directory for each wallet. In the directory would be an unchanging wallet and then a 2nd file with anything that changes. I assume the main thing that changes is the number of addresses to generate?