I have just returned to my project to create an rsync based system to 'sync' my RioCar to the music files on my server (music and rsync) which contains all the required fids etc split into an appropriate ratio for the 2 HDs on the empeg.

The script on the empeg runs ok with a small test set of files, but I'm having trouble with the bulk sync of the whole 80Gb. Here's the rsync error:

write failed on "//drive1/fids/_00004/211": No space left on device
rsync error: error in file IO (code 11) at receiver.c(278)
rsync: connection unexpectedly closed (722538 bytes read so far)
rsync error: error in rsync protocol data stream (code 12) at io.c(189)

This would imply that there's no room left on the drive. However:

empeg:/# df -H /drive?
df: Warning: cannot read table of mounted filesystems: No such file or directory
Filesystem Size Used Avail Use% Mounted on
- 30G 26G 4.0G 86% /drive0
- 60G 4.0G 56G 7% /drive1

Which indicates to me that there's plenty of room. But I have also tried to duplicate a large file in that directory and it fails with the error:

empeg://drive1/fids/_00004# cp 210 222
cp: 222: No space left on device

So it does seem to think there's no room left.

Can anyone suggest what the hell's going on here?

Run fsck on it to check that nothing is broken. Small files work then?

Can you paste the output of "tune2fs -l /dev/hdb4"?