I hired someone to move my forum. He made it totally seamless, people had no clue we moved servers (even though I made sure to post again and again about when it was happening). If you do it right, they won't notice (although there is nothing wrong with shutting down a forum for a move). Stats for our forum then: 35,000 threads, 500,000 posts, 70,000 users. (Much smaller than yours, but still, get someone who knows what they are doing and it will go fine.)
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