Hi,

I am doing rebuilds/reorgs on the live database in our company and have the same issues/things seen and a few ideas how it is working.

Sort in TempDB I have not used at the moment but normally I don't rebuild/reorg clustered indexes because they normally don't tend do fragment that much so I do them manually once a while.

In this document http://technet.microsoft.com/en-us/library/cc966402.aspx you have quite a lot of information about space usage and where, maybe there is the explanation you are looking for.

You truncated/ shrinked the log so you have gone back to, lets say 20MB every time?

Have you done this rebuilds with online=on or off?

BR Christoph