I eventually resorted to CBR for tunes which need to be gapless. Like you, VBR files only worked if the VBR header was absent, and that's not acceptable for me (because of the wrong length - Seek Tool doesn't work properly for them). The gaps are much less than half a second for me, though - more like a hiccup or click than a pause.
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Toby Speight
030103016 (80GB Mk2a, blue)
030102806 (0GB Mk2a, blue)