Haha, yea this pissed me off and took me about 30 minutes fumbling thru the internet to figure out.
The Problem
PHP says : unable to fork [buncha error crap] on line ###
PHP needs access to cmd.exe located in th %WINDOWS%SYSTEM32% directory. Most peopld would go, oh sh1t! I can't give my webusers access to that!
The Solution
1. Copy and Paste cmd.exe into the php.exe directory (cant do it as an isapi cause you need the CGI). DO NOT put it in the directory as your scripts. It needs to be in the same one as the php.exe executable.
Set permissions for the default IIS user.. i think its called "IUSR_%LOCALCOMPUTERNAME%"change (or if that doesnt work full control). Open properties for the /php/ folder, select security or sharing, share the thing, and select permissions. Just do a search for all the users on the localcomputer. Find the default IIS user, and give them POWER.
Kick yourself for ever thinking that someone would actually answer such an obscure question in a forum until 9324 days later.
No credit to me, i found this on the extended php manual with all those funny replys from developers appended to it. I suggest you download it.