First of all, it’s very hard to do stuff every week. As soon as something more important comes up, and you don’t have any personal gain from doing it, people will stop doing it. cloadmade planet.osm dumps are done regularly but they do it on company money so it’s easier.

It would be cool if you could include links in your post because I don’t know where to find this osmcut tool.
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  1. splitting .osm files from openstreetmap.*
    you can use osmosis.

*2. UK openstreetmap maps for Navigation on Garmin and Navit
*
*3. Corrupt osm file
*I don’t think so but anything is posible.

*4. mkgmap on low memory
*I’m not sure that will be fixed, but you could try to add a ticket to openstreetmap bug database. It might be hard to fix easily.