Hisashi T Fujinaka wrote:
> #    create  bootfloppy-big/boot-big1.fs (from: boot 
> USTAR.volsize.13200 netbsd)
> PAX=/usr/src/obj.i386/tooldir.NetBSD-4.99.6-i386/bin/nbpax sh 
> /usr/src/distrib/common/buildfloppies.sh  -i 
> "/usr/src/obj.i386/tooldir.NetBSD-4.99.6-i386/bin/nbinstallboot  
> -mi386 @IMAGE@ /usr/mdec/bootxx_ustarfs" -p  -m 1 -s .fs  boot-big 
> 5760 boot USTAR.volsize.13200 netbsd
> Running instboot: 
> /usr/src/obj.i386/tooldir.NetBSD-4.99.6-i386/bin/nbinstallboot -mi386 
> floppy.28328.tar /usr/mdec/bootxx_ustarfs
> Free space in last tar block: boot 44, netbsd 330,
> buildfloppies.sh: Image is 5962 bytes (5 KB) too big to fit on 1 disk
> *** Error code 1
>
>
I have similar results (sometime during iso image build):

all ===> etc/i386/floppies/bootfloppy-big
     create  bootfloppy-big/netbsd (from: 
/home/bsd/work/netbsd/src/../obj/distrib/i386/instkernel/netbsd-INSTALL.gz)
     create  bootfloppy-big/boot-big1.fs (from: boot USTAR.volsize.13200 
netbsd)
Running instboot: /home/bsd/work/netbsd/src/../tools/bin/nbinstallboot 
-mi386 floppy.14165.tar 
/home/bsd/work/netbsd/src/../obj/destdir.i386/usr/mdec/bootxx_ustarfs
Free space in last tar block: boot 492, netbsd 92,
buildfloppies.sh: Image is 3164 bytes (3 KB) too big to fit on 1 disk

*** Failed target:  boot-big1.fs
*** Failed command: PAX=/home/bsd/work/netbsd/src/../tools/bin/nbpax 
/bin/sh /home/bsd/work/netbsd/src/distrib/common/buildfloppies.sh -i 
"/home/bsd/work/netbsd/src/../tools/bin/nbinstallboot -mi386 @IMAGE@ 
/home/bsd/work/netbsd/src/../obj/destdir.i386/usr/mdec/bootxx_ustarfs" 
-p -m 1 -s .fs boot-big 5760 boot USTAR.volsize.13200 netbsd
*** Error code 1