Troubleshooting pendrive ext2fs

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Hello,

I've trouble creating an ext2/ext3/ext4 file system in a 64GBytes pendrive.

The device appears at /proc/bus/usb/devices as:

T:  Bus=01 Lev=01 Prnt=01 Port=04 Cnt=01 Dev#=  4 Spd=480 MxCh= 0
D:  Ver= 2.00 Cls=00(>ifc ) Sub=00 Prot=00 MxPS=64 #Cfgs=  1
P:  Vendor=1043 ProdID=8012 Rev= 1.00
S:  Manufacturer=Generic
S:  Product=Flash Disk
C:* #Ifs= 1 Cfg#= 1 Atr=80 MxPwr=100mA
I:* If#= 0 Alt= 0 #EPs= 2 Cls=08(stor.) Sub=06 Prot=50 Driver=usb-storage
E:  Ad=81(I) Atr=02(Bulk) MxPS= 512 Ivl=0ms
E:  Ad=02(O) Atr=02(Bulk) MxPS= 512 Ivl=0ms


It's partioned as:

Disk /dev/sdd: 67.1 GB, 67108864512 bytes
64 heads, 32 sectors/track, 64000 cylinders
Units = cilindros of 2048 * 512 = 1048576 bytes
Disk identifier: 0x4a26a3ed

Dispositivo Boot      Start         End      Blocks   Id  System
/dev/sdd1               1       64000    65535984   83  Linux


And raw partition table data is:

Disk /dev/sdd: 64 heads, 32 sectors, 64000 cylinders

Nr AF  Hd Sec  Cyl  Hd Sec  Cyl     Start      Size ID
 1 00   1   1    0  63  32 1023         32  131071968 83
 2 00   0   0    0   0   0    0          0          0 00
 3 00   0   0    0   0   0    0          0          0 00
 4 00   0   0    0   0   0    0          0          0 00


Disk was formatted with the following command:

[root@localhost ~]# mkfs.ext2 -L kingston -M /media/kingston -O large_file,extent /dev/sdd1
mke2fs 1.41.4 (27-Jan-2009)
Filesystem label=kingston
OS type: Linux
Block size=4096 (log=2)
Fragment size=4096 (log=2)
4096000 inodes, 16383996 blocks
819199 blocks (5.00%) reserved for the super user
First data block=0
Maximum filesystem blocks=0
500 block groups
32768 blocks per group, 32768 fragments per group
8192 inodes per group
Superblock backups stored on blocks:
    32768, 98304, 163840, 229376, 294912, 819200, 884736, 1605632, 2654208,
    4096000, 7962624, 11239424

Writing inode tables: done                           
Writing superblocks and filesystem accounting information: done

This filesystem will be automatically checked every 33 mounts or
180 days, whichever comes first.  Use tune2fs -c or -i to override.


And then checked:

# fsck -f -v /dev/sdd1

Resulting in:

[root@localhost ~]# fsck -v -f /dev/sdd1
fsck 1.41.4 (27-Jan-2009)
e2fsck 1.41.4 (27-Jan-2009)
Pass 1: Checking inodes, blocks, and sizes
Pass 2: Checking directory structure
Pass 3: Checking directory connectivity
Pass 4: Checking reference counts
Pass 5: Checking group summary information
Block bitmap differences:  +(32768--34306) +(65536--66049) +(98304--99842) +(131072--131585) +(163840--165378) +(196608--197121) +(229376--230914) +(262144--262657) +(294912--296450) +(327680--328193) +(360448--360961) +(393216--393729) +(425984--426497) +(458752--459265) +(491520--492033) +(524288--524801) +(557056--557569) +(589824--590337) +(622592--623105) +(655360--655873) +(688128--688641) +(720896--721409) +(753664--754177) +(786432--786945) +(819200--820738) +(851968--852481) +(884736--886274) +(917504--918017) +(950272--950785) +(983040--983553) +(1015808--1016321) +(1048576--1049089) +(1081344--1081857) +(1114112--1114625) +(1146880--1147393) +(1179648--1180161) +(1212416--1212929) +(1245184--1245697) +(1277952--1278465) +(1310720--1311233) +(1343488--1344001) +(1376256--1376769) +(1409024--1409537) +(1441792--1442305) +(1474560--1475073) +(1507328--1507841) +(1540096--1540609) +(1572864--1573377) +(1605632--1607170) +(1638400--1638913) +(1671168--1671681) +(1703936--1704449) 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+(15826944--15827457) +(15859712--15860225) +(15892480--15892993) +(15925248--15925761) +(15958016--15958529) +(15990784--15991297) +(16023552--16024065) +(16056320--16056833) +(16089088--16089601) +(16121856--16122369) +(16154624--16155137) +(16187392--16187905) +(16220160--16220673) +(16252928--16253441) +(16285696--16286209) +(16318464--16318977) +(16351232--16351745)
Fix<y>?


If I fsck without -f, /dev/sdd1 will not be checked (it's marked as clean)...

Then, if I ignore the errors, mount /dev/sdd1 at /media/kingston and do:

# PREFIX=/media/kingston/`date +%y%m%d%H%M`
# tar cjPf - /home /opt /usr/local | gpg -c -a -z0 --cipher-algo=aes256 -o ${PREFIX}.asc

It will create the backup file.

But, if I try:

# md5sum ${PREFIX}.asc > ${PREFIX}.md5

it will complain that "cannot write to device"...

I checked the device with:

# badblocks -w -v /dev/sdd1 and it went through without finding errors.

What's going wild with this particular device???

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