Alright, ironically that same flash drive I had originally used worked perfectly... isn't that always my luck?
So I tried two others, a 4GB and 8GB (Same PNY model, I have a few of those)
Both errored when trying to fill the drive with a FAT32 rounded to MiB. For the 4GB, what I did was my "usual trick" - make a small partition in the middle somewhere, then move to the left while resizing. That seems to work about 50/50, the other half of the times it errors when moving and I have to start over.
Here are the details. When it first failed to create a full partition:
GParted 0.12.0 --enable-libparted-dmraid
Libparted 2.3
Create Primary Partition #1 (fat32, 3.74 GiB) on /dev/sdb 00:00:00 ( ERROR )
create empty partition 00:00:00 ( SUCCESS )
path: /dev/sdb1
start: 2,048
end: 7,839,743
size: 7,837,696 (3.74 GiB)
set partition type on /dev/sdb1 00:00:00 ( SUCCESS )
new partition type: fat32
create new fat32 file system 00:00:00 ( ERROR )
mkdosfs -F32 -v -n "" /dev/sdb1
mkdosfs 3.0.11 (24 Dec 2010)
/dev/sdb1: No such file or directory
========================================
Now, when I moved that partition to fill the drive:
GParted 0.12.0 --enable-libparted-dmraid
Libparted 2.3
Move /dev/sdb1 to the left and grow it from 291.00 MiB to 3.74 GiB 00:00:04 ( SUCCESS )
calibrate /dev/sdb1 00:00:00 ( SUCCESS )
path: /dev/sdb1
start: 2,070,528
end: 2,666,495
size: 595,968 (291.00 MiB)
check file system on /dev/sdb1 for errors and (if possible) fix them 00:00:00 ( SUCCESS )
dosfsck -a -w -v /dev/sdb1
dosfsck 3.0.11 (24 Dec 2010)
dosfsck 3.0.11, 24 Dec 2010, FAT32, LFN
Checking we can access the last sector of the filesystem
Boot sector contents:
System ID "mkdosfs"
Media byte 0xf8 (hard disk)
512 bytes per logical sector
4096 bytes per cluster
32 reserved sectors
First FAT starts at byte 16384 (sector 32)
2 FATs, 32 bit entries
299008 bytes per FAT (= 584 sectors)
Root directory start at cluster 2 (arbitrary size)
Data area starts at byte 614400 (sector 1200)
74346 data clusters (304521216 bytes)
62 sectors/track, 124 heads
0 hidden sectors
595968 sectors total
Reclaiming unconnected clusters.
Checking free cluster summary.
/dev/sdb1: 0 files, 1/74346 clusters
grow partition from 291.00 MiB to 1.27 GiB 00:00:00 ( SUCCESS )
old start: 2,070,528
old end: 2,666,495
old size: 595,968 (291.00 MiB)
new start: 2,048
new end: 2,666,495
new size: 2,664,448 (1.27 GiB)
move file system to the left 00:00:01 ( SUCCESS )
using libparted
shrink partition from 1.27 GiB to 291.00 MiB 00:00:00 ( SUCCESS )
old start: 2,048
old end: 2,666,495
old size: 2,664,448 (1.27 GiB)
new start: 2,048
new end: 598,015
new size: 595,968 (291.00 MiB)
check file system on /dev/sdb1 for errors and (if possible) fix them 00:00:00 ( SUCCESS )
dosfsck -a -w -v /dev/sdb1
dosfsck 3.0.11 (24 Dec 2010)
dosfsck 3.0.11, 24 Dec 2010, FAT32, LFN
Checking we can access the last sector of the filesystem
Boot sector contents:
System ID "MSWIN4.1"
Media byte 0xf8 (hard disk)
512 bytes per logical sector
4096 bytes per cluster
44 reserved sectors
First FAT starts at byte 22528 (sector 44)
2 FATs, 32 bit entries
297984 bytes per FAT (= 582 sectors)
Root directory start at cluster 2 (arbitrary size)
Data area starts at byte 618496 (sector 1208)
74345 data clusters (304517120 bytes)
62 sectors/track, 124 heads
2048 hidden sectors
595968 sectors total
Reclaiming unconnected clusters.
Checking free cluster summary.
/dev/sdb1: 0 files, 1/74345 clusters
grow partition from 291.00 MiB to 3.74 GiB 00:00:00 ( SUCCESS )
old start: 2,048
old end: 598,015
old size: 595,968 (291.00 MiB)
new start: 2,048
new end: 7,839,743
new size: 7,837,696 (3.74 GiB)
check file system on /dev/sdb1 for errors and (if possible) fix them 00:00:00 ( SUCCESS )
dosfsck -a -w -v /dev/sdb1
dosfsck 3.0.11 (24 Dec 2010)
dosfsck 3.0.11, 24 Dec 2010, FAT32, LFN
Checking we can access the last sector of the filesystem
Boot sector contents:
System ID "MSWIN4.1"
Media byte 0xf8 (hard disk)
512 bytes per logical sector
4096 bytes per cluster
44 reserved sectors
First FAT starts at byte 22528 (sector 44)
2 FATs, 32 bit entries
297984 bytes per FAT (= 582 sectors)
Root directory start at cluster 2 (arbitrary size)
Data area starts at byte 618496 (sector 1208)
74345 data clusters (304517120 bytes)
62 sectors/track, 124 heads
2048 hidden sectors
595968 sectors total
Reclaiming unconnected clusters.
Checking free cluster summary.
/dev/sdb1: 0 files, 1/74345 clusters
grow file system to fill the partition 00:00:03 ( SUCCESS )
using libparted
========================================
This is on my 8GB flash drive, failed partition creation:
GParted 0.12.0 --enable-libparted-dmraid
Libparted 2.3
Create Primary Partition #1 (fat32, 7.46 GiB) on /dev/sdc 00:00:00 ( ERROR )
create empty partition 00:00:00 ( SUCCESS )
path: /dev/sdc1
start: 2,048
end: 15,638,527
size: 15,636,480 (7.46 GiB)
set partition type on /dev/sdc1 00:00:00 ( SUCCESS )
new partition type: fat32
create new fat32 file system 00:00:00 ( ERROR )
mkdosfs -F32 -v -n "" /dev/sdc1
mkdosfs 3.0.11 (24 Dec 2010)
/dev/sdc1: No such file or directory
========================================
On this one I tried your initial suggestion and rounded it to cylinders instead of MiB. That worked, here's the details:
GParted 0.12.0 --enable-libparted-dmraid
Libparted 2.3
Create Primary Partition #1 (fat32, 7.45 GiB) on /dev/sdc 00:00:13 ( SUCCESS )
create empty partition 00:00:00 ( SUCCESS )
path: /dev/sdc1
start: 63
end: 15,631,244
size: 15,631,182 (7.45 GiB)
set partition type on /dev/sdc1 00:00:00 ( SUCCESS )
new partition type: fat32
create new fat32 file system 00:00:13 ( SUCCESS )
mkdosfs -F32 -v -n "" /dev/sdc1
mkdosfs 3.0.11 (24 Dec 2010)
/dev/sdc1 has 255 heads and 63 sectors per track,
logical sector size is 512,
using 0xf8 media descriptor, with 15631182 sectors;
file system has 2 32-bit FATs and 8 sectors per cluster.
FAT size is 15240 sectors, and provides 1950083 clusters.
There are 32 reserved sectors.
Volume ID is 63badb0f, no volume label.
========================================
And finally, I resized it to fill that extra couple MB's that were left at the end, rounded to MiB this time, which worked:
GParted 0.12.0 --enable-libparted-dmraid
Libparted 2.3
Grow /dev/sdc1 from 7.45 GiB to 7.46 GiB 00:00:05 ( SUCCESS )
calibrate /dev/sdc1 00:00:00 ( SUCCESS )
path: /dev/sdc1
start: 63
end: 15,631,244
size: 15,631,182 (7.45 GiB)
check file system on /dev/sdc1 for errors and (if possible) fix them 00:00:01 ( SUCCESS )
dosfsck -a -w -v /dev/sdc1
dosfsck 3.0.11 (24 Dec 2010)
dosfsck 3.0.11, 24 Dec 2010, FAT32, LFN
Checking we can access the last sector of the filesystem
Boot sector contents:
System ID "mkdosfs"
Media byte 0xf8 (hard disk)
512 bytes per logical sector
4096 bytes per cluster
32 reserved sectors
First FAT starts at byte 16384 (sector 32)
2 FATs, 32 bit entries
7802880 bytes per FAT (= 15240 sectors)
Root directory start at cluster 2 (arbitrary size)
Data area starts at byte 15622144 (sector 30512)
1950083 data clusters (7987539968 bytes)
63 sectors/track, 255 heads
0 hidden sectors
15631182 sectors total
Reclaiming unconnected clusters.
Checking free cluster summary.
/dev/sdc1: 0 files, 1/1950083 clusters
grow partition from 7.45 GiB to 7.46 GiB 00:00:00 ( SUCCESS )
old start: 63
old end: 15,631,244
old size: 15,631,182 (7.45 GiB)
new start: 63
new end: 15,638,527
new size: 15,638,465 (7.46 GiB)
check file system on /dev/sdc1 for errors and (if possible) fix them 00:00:01 ( SUCCESS )
dosfsck -a -w -v /dev/sdc1
dosfsck 3.0.11 (24 Dec 2010)
dosfsck 3.0.11, 24 Dec 2010, FAT32, LFN
Checking we can access the last sector of the filesystem
Boot sector contents:
System ID "mkdosfs"
Media byte 0xf8 (hard disk)
512 bytes per logical sector
4096 bytes per cluster
32 reserved sectors
First FAT starts at byte 16384 (sector 32)
2 FATs, 32 bit entries
7802880 bytes per FAT (= 15240 sectors)
Root directory start at cluster 2 (arbitrary size)
Data area starts at byte 15622144 (sector 30512)
1950083 data clusters (7987539968 bytes)
63 sectors/track, 255 heads
0 hidden sectors
15631182 sectors total
Reclaiming unconnected clusters.
Checking free cluster summary.
/dev/sdc1: 0 files, 1/1950083 clusters
grow file system to fill the partition 00:00:03 ( SUCCESS )
using libparted
========================================
Hopefully that helps you. It seems really odd, that it says it can't find that folder, I've never seen such an error before, but it does it on a majority of drives I try it on as you can see from the stuff I posted. Rounding to cylinders usually works, however I've had that fail as well when the older version of GParted never failed.