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I recently bought a 8GB USB flash disk. I created a fat32 filesystem (using mkfs.vfat) on the whole drive (/dev/sdb1).

df -h shows approximately 8GB available, but when I try to extract an archive on the disk, the kernel raises No space left on device exceptions at about 812MB of occupation, and df stills show plenty of space available.

I tried the same manipulation using an ext3 filesystem, without any problem.

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That's definitely not hardware (unless i'm incredibly unlucky). I tried with an other brand new usb drive, with exactly the same result. The system claims "No space left on device" at 812MB. –  swordofpain Dec 4 '10 at 23:12
    
I don't know where the answer is gone, so here is the mkfs command I used : mkfs.fsck -F 32 -n katana /dev/sdb1 –  swordofpain Dec 4 '10 at 23:13
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