The "make usb-image" command should call genext2fs with the -i arg for large file systems else you do not have enough inodes if you are simply adding extra space to execute various work loads.
make usb-image-loop
configure --enable-rootfs=glibc_small --enable-board=qemux86 make usb-image IMGARGS="--ext2-mb=2000 --no-rm" mkdir /tmp/jj sudo mount -o loop export/img_tmp.2 /tmp/jj ; df -i /tmp/jj ; sudo umount /tmp/jj Filesystem Inodes IUsed IFree IUse% Mounted on /dev/loop0 4000 1225 2775 31% /tmp/jj That will not be nearly enough!