to small a size was used (probably a result of my using reiserfs).
#############################################################
# How much KB we want to add to the calculated size for slack space
-GENEXT2_ADDTOROOTSIZE=4096
+#GENEXT2_ADDTOROOTSIZE=4096
+GENEXT2_ADDTOROOTSIZE=16384
GENEXT2_REALSIZE=$(subst total,, $(shell du $(TARGET_DIR) -s -c -k | grep total ))
GENEXT2_SIZE=$(shell expr $(GENEXT2_REALSIZE) + $(GENEXT2_ADDTOROOTSIZE))
# We currently add about 400 device nodes, so add that into the total