Comment 82 for bug 1065281

Another update from Stuart regarding mkdosfs/mkfs.vfat that may be relevant and it may lend some ammo to possibly adding the "-s 1" flag to the mkdosfs command mentioned above?

"So it looks like mkdosfs / mkfs.vfat is calculating an initial guess for "bs.cluster_size" (the internal variable name) based on the size of the disk, just assuming 512 bytes per sector.

The assumption is implicit, because they are using numbers from a table in a Microsoft document, and the number "512" (or any sort of sectors per track) doesn't show up in the code here, so that is probably why it got missed. They clearly take into account sectors per track elsewhere in the code.

The code will actually increase the number of sectors in a cluster until it fits nicely, but it will not decrease it.

I'll try to get a patch in upstream to fix this. For now, though, it should work ok to just use "-s 1", as far as I can tell."