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4000 uniques/day and its struggling? must be using mod_perl or something. if you can ditch mod_perl and make some more tuning (replace some code with periodically updated static text), you may be able to see an incredibly increase in performance.
with good code, you should be able to handle at least 1 million hits/day, not including images (ie just PHP or non-mod_perl CGI). images could be handled on the same server or a second server, several dozen million per day depending on size.
now if you want load balancing for the purposes of redundancy, that's another story. you should still get way more out of your current hardware though.
btw, you say it was done by one of the best programmers in the industry? only one comes to mind that would make that claim. are you, by chance, using drewstar?
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