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[ts-7000] How to copy SD card with different geometry?

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Subject: [ts-7000] How to copy SD card with different geometry?
From: "whiffwaffle" <>
Date: Sat, 28 Feb 2009 06:18:43 -0000
I have been using 7400's for almost a year now. I originally made a 1g
SD flash card that it boots from and then used dd to make copies. This
worked fine for months, but now I am having trouble getting the same
1g flash card.

When I try to dd the image to any other 1g flash card, it boots up and
works fine, but if I remove power and it runs fsck, it locks up at
2.9%. If I put it in my Linux PC and fsck it, I get many errors:

"Error reading block 41252 (Attempt to read block from filesystem
resulted in short read) while getting next inode from scan."

I posted about a similar problem a few months ago and got no response,
but I found a supply of the cards I was using so it wasn't an issue.
My supply of cards is getting critically low so I need to find a
solution to this soon. 

I suspect it's a geometry problem. Here is the output of fdisk for
each card:

SD card that works:
Disk /dev/sdc: 1019 MB, 1019215872 bytes
16 heads, 32 sectors/track, 3888 cylinders
Units = cylinders of 512 * 512 = 262144 bytes
Disk identifier: 0x00000000

   Device Boot      Start         End      Blocks   Id  System
/dev/sdc1               1           6        1520   da  Non-FS data
/dev/sdc2               7          10        1024   da  Non-FS data
/dev/sdc3              20        3850      980736   83  Linux


New SD card that locks up:
Disk /dev/sdc: 1023 MB, 1023934464 bytes
16 heads, 32 sectors/track, 3906 cylinders
Units = cylinders of 512 * 512 = 262144 bytes
Disk identifier: 0x00000000

   Device Boot      Start         End      Blocks   Id  System
/dev/sdc1               1           6        1520   da  Non-FS data
/dev/sdc2               7          10        1024   da  Non-FS data
/dev/sdc3              20        3850      980736   83  Linux

I also tried what I originally did to make the 1g card, which was
dd'ing the 512m image from the Technologic web site and then resizing
the file system. That does not work either. I've tried 5-6 different
SD cards, both 1g and 2g and they all lock up during fsck.

Is there a better way than dd to make a duplicate of the card short of
completely reinstalling and reconfiguring everything?

Any help would be greatly appreciated.





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