It all sounds good except the 60,000 forums part! Honestly, I see sites slow down with over a 1,000 forums. I would probably split it into a lot less forums and then hire a programmer to use tags (probably better than prefixes in this instance) for all of this. Basically the code would need to make it so when a user wants to ask a question, and they came to the new thread page from a specific product page, it gets tagged with that product. And, when a user wants to search on a product, they end up doing a tag search instead which would bring up all threads about that product.
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