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It can still make those pages go much more slowly
It doesn't matter that it's "just" two pages, it matters that it happens
And you're forgetting people who choose "Remember my login" and thus normally don't login again. Those people would be unbannable. Thus, it does need to be checked on every pageview (otherwise you can stay unbanned just by never letting your login expire).

hcgtv: Indeed, that's why I have php.ini where I have it (I seem to remember instructions that put it in the WINDOWS folder, but I can't seem to find them anymore)
I just remember having issues when I forgot where my php.ini file was and tried editing the wrong one

Configuration File (php.ini) Path  C:\php5\php.ini 
That is where you're editing, right (I know I have PHP set up so that php.ini is in the Windows folder and I believe that's a suggested way to do it)?

Did you load the MySQL extension?

It means you're editing your code and making mistakes when you do

And from testing my best guess is that the problem is with thttpd not working properly when around 700 characters or more of POST data is sent.

The right data? How should I know, it's your login info
Go talk to your host about the information you should enter

I don't have any specific stats for PunBB, but here's some phpBB ones
http://www.phpbb.com/phpBB/viewtopic.php?t=48609
http://www.phpbb.com/phpBB/viewtopic.php?p=61823

So yeah, it depends a lot on where you have rows (ie: a row in posts is almost certainly larger than a row in users, and a longer post has a larger size). But IMO, 10MB is very small

And why can't you change it? There are plenty of hosts, free or otherwise, that at the VERY least give you more space for your databases than that

I'd be interested in trying to figure out where this is going wrong
Could you send me an email so we could try and work out some way I could play around with it a little and try and see what the problem is?

I'd suggest making sure "word" in the search_words table is set as varbinary (or varchar with a binary attribute)
Like Rickard explains here

Then it can't be included via PHP

However, if you really must, here's the way to do it:
Open extern.php

FIND

define('PUN_ROOT', './');

REPLACE WITH

if (!defined('PUN_ROOT'))
    define('PUN_ROOT', './');

Then, add the following code to your page (where you want to include extern.php):

define('PUN_ROOT', $_SERVER['DOCUMENT_ROOT'].'/');
$temp_get = $_GET;
$_GET = array();
$_GET['action'] = 'active';
$_GET['show'] = '10';
include $_SERVER['DOCUMENT_ROOT'].'/forum/extern.php';
$_GET = array();
$_GET = $temp_get;

Adjust paths as necessary

Why would reinstalling do anything?
You can not include extern.php when the file including it is not in the same folder as extern.php
You also can not use $_GET variables in a local filename
So, the fix is to call it via its URL (the way you would see it in a browser)