D-lexy,
I am curious about a few things. First, let me tell you what I have at work. I have an N-class server in full production mode. My /usr filesystem is only 1.6 GB. This is the standard for new Boxes in my corporate environment. All of my boxes are between 1.2 and 1.6 GB for /usr.
How much software/utilities do you have loaded on this box? 1.6GB seems like plenty to me. However, your case may be unusual.
Regarding your question about filesystem reworking of /usr, that can be very dangerous for OS filesystems. Normally you have to make a backup and then add disks and recreate the filesystems and then Re-load the OS. This is a simplistic description, but close. /usr is an OS filesystem.
You can usually add disks to an OS filesystem without too much problem. Just go to single user mode and make the necessary changes. However, to use a totally different disk for /usr requires much more work. At least it does in my environment.
