cloned sd card is not booting

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I am getting far enough into my system build that I don't want to go back to square one everytime I mess up. So I decided I SHOULD be able to clone my boot drive with:

sudo dd if=/dev/sdb of=/dev/sdc bs=4096 conv=notrunc,noerror; sync

And I did check that my working card is in sdb and the target is sdc. Note that the target drive has been used for prior testing.

But this cloned card fails to boot, so there is something wrong with the above command. Here is the end of what I am seeing on the console in the boot:

         Mounting Configuration File System...
[  OK  ] Mounted Configuration File System.
[ OK ] Found device /dev/disk/by-uuid/1dc878de-92d2-4a66-b352-f055a32473b9.
[  OK  ] Started dracut initqueue hook.
[  OK  ] Started Show Plymouth Boot Screen.
[  OK  ] Reached target Paths.
[  OK  ] Reached target Basic System.
         Starting dracut pre-mount hook...
[  OK  ] Reached target Remote File Systems (Pre).
[  OK  ] Reached target Remote File Systems.
Starting File System Check on /dev/disk/by-uuid/1dc8...f055a32473b9... [ 13.911063] systemd-fsck[368]: _/: The filesystem size (according to the superblock) is 3587707 blocks
[  OK  ] Started dracut pre-mount hook.
[ 13.919598] systemd-fsck[368]: The physical size of the device is 3548795 blocks [ 13.937109] systemd-fsck[368]: Either the superblock or the partition table is likely to be corrupt! [ 13.944962] systemd-fsck[368]: _/: UNEXPECTED INCONSISTENCY; RUN fsck MANUALLY.
[   13.950853] systemd-fsck[368]: (i.e., without -a or -p options)
[ OK ] Started File System Check on /dev/disk/by-uuid/1dc87...2-f055a32473b9.
         Mounting /sysroot...
[   14.483857] random: nonblocking pool is initialized
[ 14.571964] EXT4-fs (mmcblk0p3): bad geometry: block count 3587707 exceeds size of device (3548795 blocks)
[FAILED] Failed to mount /sysroot.
See 'systemctl status sysroot.mount' for details.
[DEPEND] Dependency failed for Initrd Root File System.
[DEPEND] Dependency failed for Reload Configuration from the Real Root.
[  OK  ] Stopped dracut pre-pivot and cleanup hook.
[  OK  ] Stopped target Initrd Default Target.
[  OK  ] Stopped dracut mount hook.
[  OK  ] Reached target Initrd File Systems.
[  OK  ] Stopped target Basic System.
[  OK  ] Stopped target System Initialization.
         Starting Emergency Shel
Generating "/run/initramfs/rdsosreport.txt"


Entering emergency mode. Exit the shell to continue.
Type "journalctl" to view system logs.
You might want to save "/run/initramfs/rdsosreport.txt" to a USB stick or /boot
after mounting them and attach it to a bug report.


:/# [ 17.458499] systemd-udevd (321) used greatest stack depth: 5248 bytes left [ 17.497871] systemd-udevd (320) used greatest stack depth: 5020 bytes left

============================================

I see these stack messages regularly even when things are working.

I hope someone can help me with the cloning, as it will really simplify my testing.

thanks



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