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I ran into this problem, even though outlook 2003 supports a theoretical 33 terabyte .pst folder size, it gave messages that it was full at only about 2 gigabytes:
:: Quote ::Outlook 2003 supports two different Personal Folders file formats, the older Personal Folders file and a new Unicode-compatible Personal Folders file format that's capable of growing to around 33TB (yes, that's terabytes). The ANSI Personal Folders files still have a size limit of 2GB.
Which of course is a problem if you set up outlook without realizing this issue.
More in depth article here.
Microsoft has this, which sounds like the best solution:
:: Quote ::HideCreate a new data file
1. On the File menu, point to New, and then click Outlook Data File.
2. To create a Microsoft Outlook Personal Folders File (.pst) that offers greater storage capacity for items and folders and supports multilingual Unicode data, click OK.
3. In the File name box, type a name for the file, and then click OK.
4. In the Name box, type a display name for the .pst folder.
5. Select any other options you want, and then click OK.
The name of the folder associated with the data file appears in the Folder List (Folder List: Displays the folders available in your mailbox. To view subfolders, click the plus sign (+) next to the folder. If the Folder List is not visible, on the Go menu, click Folder List.). To view the Folder List, on the Go menu, click Folder List. By default, the folder will be called Personal Folders.
HideImport items to the new data file
1. On the File menu, click Import and Export.
2. Click Import from another program or file, and then click Next.
3. Click Personal Folder File (.pst), and then click Next.
4. In the File to import box, specify the path and file name of the old non-Unicode Microsoft Outlook 97-2002 Personal Folders File (.pst) file you want to import and click Next.
5. Select Import items into the same folder in: and select the name of your new Unicode Personal Folders File (.pst).
6. Follow the remaining instructions in the Import and Export Wizard.
Then you have to change the default mail delivery pst file to the new one, that's using the wizard, tools -> email accounts -> change account -> view or change existing email accounts -> New Outlook data file. Once you've browsed to the new one, you need to select it from the dropdown list, it took me a few tries until it stuck.
Then you restart Outlook and it will be using the new pst file, the unicode one. Note: for new pst files, you must pick the 'personal folder file', not the outlook 2002 format when creating it.
So at that point the question becomes: how to transfer an ansi formatted pst file to a unicode formatted one....
:: Quote ::o force Unicode or ANSI PSTs, navigate to HKEY_CURRENT_USER\Software\Microsoft\Office⏻.0\Outlook.
Add the NewPSTFormat value with one of the following values:
* Prefer Unicode PST: 0 (default)
* Prefer ANSI PST: 1
* Enforce Unicode PST: 2
* Enforce ANSI PST: 3
By using a value of 2 or 3, you can restrict all new .PST files to either the old format or the new format.src
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