1) vboptions > user reg options > email addy to notify about new members
2) you need to find out why it is being flaky like that. It sounds more like a server issue than any sort of vbulletin issue. The only other thing I can think of is you don't have your mods set to receive email for each forum. check Forums & Mods > Show all mods > find a mod and select the forum and hit Edit and make sure Email Prefs are set correctly.
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