AVR Freaks

So coming back to this a bit with what I feel learned info.

Looking at my OP

 Size before:
        AVR Memory Usage
        ----------------
        Device: atmega328p
        Program:   28704 bytes (87.6% Full)
        (.text + .data + .bootloader)
        Data:       1227 bytes (59.9% Full)
        (.data + .bss + .noinit)
        Size after:
        AVR Memory Usage
        ----------------
        Device: atmega328p
        Program:   28704 bytes (87.6% Full)
        (.text + .data + .bootloader)
        Data:       1227 bytes (59.9% Full)
        (.data + .bss + .noinit)
        -------- end --------      

I see this in my make file

COFFCONVERT = $(OBJCOPY) --debugging
COFFCONVERT += --change-section-address .data-0x800000
COFFCONVERT += --change-section-address .bss-0x800000
COFFCONVERT += --change-section-address .noinit-0x800000
COFFCONVERT += --change-section-address .eeprom-0x810000

Still completely unclear what this (.text + .data + .bootloader) is coming from though i see the  (.data + .bss + .noinit) in the makefile. but, nnder a the debug: area that is never called.

This is the makefile as I have it, guessing its a huge mess or overkill.

MCU = atmega328p
F_CPU = 12000000
DEBUG_LEVEL=0
FORMAT = ihex
TARGET = main
OBJDIR =  .
SOURCEDIR = ../BASE_2.0/
# List C source files here. (C dependencies are automatically generated.)
SRC =  /usbdrv/usbdrv.c main.c $(SOURCEDIR)gamepad.c $(SOURCEDIR)gcn64_protocol.c $(SOURCEDIR)i2c.c $(SOURCEDIR)gc.c $(SOURCEDIR)db9.c $(SOURCEDIR)snes.c $(SOURCEDIR)saturn.c $(SOURCEDIR)twelve.c $(SOURCEDIR)jaguar.c $(SOURCEDIR)intellivision.c  $(SOURCEDIR)wii.c $(SOURCEDIR)psx.c $(SOURCEDIR)dreamCast.c $(SOURCEDIR)psx.c $(SOURCEDIR)n64.c $(SOURCEDIR)wii.c $(SOURCEDIR)atmark.c $(SOURCEDIR)gameport.c
# List C++ source files here. (C dependencies are automatically generated.)
CPPSRC =
# List Assembler source files here.
ASRC = /usbdrv/usbdrvasm.S $(SOURCEDIR)dcRead.S
# Optimization level, can be [0, 1, 2, 3, s].
#     0 = turn off optimization. s = optimize for size.
#     (Note: 3 is not always the best optimization level. See avr-libc FAQ.)
OPT = s
#s %80.07
#1 %86.9
#2 %85.5
#3 %110.4

# Debugging format.
#     Native formats for AVR-GCC's -g are dwarf-2 [default] or stabs.
#     AVR Studio 4.10 requires dwarf-2.
#     AVR [Extended] COFF format requires stabs, plus an avr-objcopy run.
DEBUG = dwarf-2

# List any extra directories to look for include files here.
#     Each directory must be seperated by a space.
#     Use forward slashes for directory separators.
#     For a directory that has spaces, enclose it in quotes.
EXTRAINCDIRS = usbdrv

# Compiler flag to set the C Standard level.
#     c89   = "ANSI" C
#     gnu89 = c89 plus GCC extensions
#     c99   = ISO C99 standard (not yet fully implemented)
#     gnu99 = c99 plus GCC extensions
CSTANDARD = -std=gnu99

# Place -D or -U options here for C sources
CDEFS = -DF_CPU=$(F_CPU)L
#-DDEBUG_LEVEL=$(DEBUG_LEVEL)


# Place -D or -U options here for ASM sources
ADEFS = -DF_CPU=$(F_CPU)

# Place -D or -U options here for C++ sources
CPPDEFS = -DF_CPU=$(F_CPU)UL
#CPPDEFS += -D__STDC_LIMIT_MACROS
#CPPDEFS += -D__STDC_CONSTANT_MACROS

#---------------- Compiler Options C ----------------
#  -g*:          generate debugging information
#  -O*:          optimization level
#  -f...:        tuning, see GCC manual and avr-libc documentation
#  -Wall...:     warning level
#  -Wa,...:      tell GCC to pass this to the assembler.
#    -adhlns...: create assembler listing
#CFLAGS = -g$(DEBUG)
CFLAGS += $(CDEFS)
CFLAGS += -O$(OPT)
CFLAGS += -Wall

#force smaller size!
CFLAGS += -fno-inline-small-functions
CFLAGS += -ffunction-sections
CFLAGS += --save-temps
#LDFLAGS += -Wl,--relax
#LDFLAGS += -Wl,--gc-sections
# causes issues ---    CFLAGS += -fwhole-program --combine

CFLAGS += -Wstrict-prototypes
#CFLAGS += -mshort-calls
#CFLAGS += -fno-unit-at-a-time
#CFLAGS += -Wundef
#CFLAGS += -Wunreachable-code
#CFLAGS += -Wsign-compare
CFLAGS += -Wa,-adhlns=$(<:%.c=$(OBJDIR)/%.lst)
CFLAGS += $(patsubst %,-I%,$(EXTRAINCDIRS))
CFLAGS += $(CSTANDARD)


#---------------- Assembler Options ----------------
#  -Wa,...:   tell GCC to pass this to the assembler.
#  -adhlns:   create listing
#  -gstabs:   have the assembler create line number information; note that
#             for use in COFF files, additional information about filenames
#             and function names needs to be present in the assembler source
#             files -- see avr-libc docs [FIXME: not yet described there]
#  -listing-cont-lines: Sets the maximum number of continuation lines of hex
#       dump that will be displayed for a given single line of source input.
ASFLAGS = $(ADEFS) -Wa,-adhlns=$(<:%.S=$(OBJDIR)/%.lst),-gstabs,--listing-cont-lines=100

#---------------- Library Options ----------------
# Minimalistic printf version
PRINTF_LIB_MIN = -Wl,-u,vfprintf -lprintf_min

# Floating point printf version (requires MATH_LIB = -lm below)
PRINTF_LIB_FLOAT = -Wl,-u,vfprintf -lprintf_flt

# If this is left blank, then it will use the Standard printf version.
PRINTF_LIB =
#PRINTF_LIB = $(PRINTF_LIB_MIN)
#PRINTF_LIB = $(PRINTF_LIB_FLOAT)

# Minimalistic scanf version
SCANF_LIB_MIN = -Wl,-u,vfscanf -lscanf_min

# Floating point + %[ scanf version (requires MATH_LIB = -lm below)
SCANF_LIB_FLOAT = -Wl,-u,vfscanf -lscanf_flt

# If this is left blank, then it will use the Standard scanf version.
SCANF_LIB =
#SCANF_LIB = $(SCANF_LIB_MIN)
#SCANF_LIB = $(SCANF_LIB_FLOAT)


MATH_LIB = -lm


# List any extra directories to look for libraries here.
#     Each directory must be seperated by a space.
#     Use forward slashes for directory separators.
#     For a directory that has spaces, enclose it in quotes.
EXTRALIBDIRS =

#---------------- External Memory Options ----------------

# 64 KB of external RAM, starting after internal RAM (ATmega128!),
# used for variables (.data/.bss) and heap (malloc()).
#EXTMEMOPTS = -Wl,-Tdata=0x801100,--defsym=__heap_end=0x80ffff

# 64 KB of external RAM, starting after internal RAM (ATmega128!),
# only used for heap (malloc()).
#EXTMEMOPTS = -Wl,--section-start,.data=0x801100,--defsym=__heap_end=0x80ffff

EXTMEMOPTS =

#---------------- Linker Options ----------------
#  -Wl,...:     tell GCC to pass this to linker.
#    -Map:      create map file
#    --cref:    add cross reference to  map file
LDFLAGS = -Wl,-Map=$(TARGET).map,--cref
LDFLAGS += $(EXTMEMOPTS)
LDFLAGS += $(patsubst %,-L%,$(EXTRALIBDIRS))
LDFLAGS += $(PRINTF_LIB) $(SCANF_LIB) $(MATH_LIB)
#LDFLAGS += -T linker_script.x


#---------------- Programming Options (avrdude) ----------------

# Programming hardware
# Type: avrdude -c ?
# to get a full listing.
#
AVRDUDE_PROGRAMMER = stk500

# com1 = serial port. Use lpt1 to connect to parallel port.
AVRDUDE_PORT = usb

AVRDUDE_WRITE_FLASH = -Uflash:w:$(TARGET).hex -B 1.0

AVRDUDE_FLAGS = -p $(MCU) -P $(AVRDUDE_PORT) -c $(AVRDUDE_PROGRAMMER)
AVRDUDE_FLAGS += $(AVRDUDE_NO_VERIFY)
AVRDUDE_FLAGS += $(AVRDUDE_VERBOSE)
AVRDUDE_FLAGS += $(AVRDUDE_ERASE_COUNTER)


# Define programs and commands.
SHELL = sh
CC = avr-gcc
OBJCOPY = avr-objcopy
OBJDUMP = avr-objdump
SIZE = avr-size
AR = avr-ar rcs
NM = avr-nm
AVRDUDE = avrdude
REMOVE = rm -f
REMOVEDIR = rm -rf
COPY = cp
WINSHELL = cmd


# Define Messages
# English
MSG_ERRORS_NONE = Errors: none
MSG_BEGIN = -------- begin --------
MSG_END = --------  end  --------
MSG_SIZE_BEFORE = Size before:
MSG_SIZE_AFTER = Size after:
MSG_COFF = Converting to AVR COFF:
MSG_EXTENDED_COFF = Converting to AVR Extended COFF:
MSG_FLASH = Creating load file for Flash:
MSG_EEPROM = Creating load file for EEPROM:
MSG_EXTENDED_LISTING = Creating Extended Listing:
MSG_SYMBOL_TABLE = Creating Symbol Table:
MSG_LINKING = Linking:
MSG_COMPILING = Compiling C:
MSG_COMPILING_CPP = Compiling C++:
MSG_ASSEMBLING = Assembling:
MSG_CLEANING = Cleaning project:
MSG_CREATING_LIBRARY = Creating library:

# Define all object files.
OBJ = $(SRC:%.c=$(OBJDIR)/%.o) $(CPPSRC:%.cpp=$(OBJDIR)/%.o) $(ASRC:%.S=$(OBJDIR)/%.o)

# Define all listing files.
LST = $(SRC:%.c=$(OBJDIR)/%.lst) $(CPPSRC:%.cpp=$(OBJDIR)/%.lst) $(ASRC:%.S=$(OBJDIR)/%.lst)

# Compiler flags to generate dependency files.
GENDEPFLAGS = -MMD -MP -MF .dep/$(@F).d

# Combine all necessary flags and optional flags.
# Add target processor to flags.
ALL_CFLAGS = -mmcu=$(MCU) -I. $(CFLAGS) $(GENDEPFLAGS)
ALL_CPPFLAGS = -mmcu=$(MCU) -I. -x c++ $(CPPFLAGS) $(GENDEPFLAGS)
ALL_ASFLAGS = -mmcu=$(MCU) -I. -x assembler-with-cpp $(ASFLAGS)


# Default target.
all: begin gccversion sizebefore build sizeafter end

# Change the build target to build a HEX file or a library.
build: elf hex eep lss sym
#build: lib


elf: $(TARGET).elf
hex: $(TARGET).hex
eep: $(TARGET).eep
lss: $(TARGET).lss
sym: $(TARGET).sym
LIBNAME=lib$(TARGET).a
lib: $(LIBNAME)


# Eye candy.
# AVR Studio 3.x does not check make's exit code but relies on
# the following magic strings to be generated by the compile job.
begin:
    @echo
    @echo $(MSG_BEGIN)
    
end:
    @echo $(MSG_END)
    @echo


# Display size of file.
HEXSIZE = $(SIZE) --target=$(FORMAT) $(TARGET).hex
ELFSIZE = $(SIZE) --mcu=$(MCU) --format=avr $(TARGET).elf

sizebefore:

    @if test -f $(TARGET).elf; then echo; echo $(MSG_SIZE_BEFORE); $(ELFSIZE); \
    2>/dev/null; echo; fi

sizeafter:
    @if test -f $(TARGET).elf; then echo; echo $(MSG_SIZE_AFTER); $(ELFSIZE); \
    2>/dev/null; echo; fi


# Display compiler version information.
gccversion :
    @$(CC) --version


# Program the device.  
program: $(TARGET).hex $(TARGET).eep
    $(AVRDUDE) $(AVRDUDE_FLAGS) $(AVRDUDE_WRITE_FLASH) $(AVRDUDE_WRITE_EEPROM)


# Generate avr-gdb config/init file which does the following:
#     define the reset signal, load the target file, connect to target, and set
#     a breakpoint at main().
gdb-config:
    @$(REMOVE) $(GDBINIT_FILE)
    @echo define reset >> $(GDBINIT_FILE)
    @echo SIGNAL SIGHUP >> $(GDBINIT_FILE)
    @echo end >> $(GDBINIT_FILE)
    @echo file $(TARGET).elf >> $(GDBINIT_FILE)
    @echo target remote $(DEBUG_HOST):$(DEBUG_PORT)  >> $(GDBINIT_FILE)
ifeq ($(DEBUG_BACKEND),simulavr)
    @echo load  >> $(GDBINIT_FILE)
endif
    @echo break main >> $(GDBINIT_FILE)


coff: $(TARGET).elf
    @echo
    @echo $(MSG_COFF) $(TARGET).cof
    $(COFFCONVERT) -O coff-avr $< $(TARGET).cof


extcoff: $(TARGET).elf
    @echo
    @echo $(MSG_EXTENDED_COFF) $(TARGET).cof
    $(COFFCONVERT) -O coff-ext-avr $< $(TARGET).cof


# Create final output files (.hex, .eep) from ELF output file.
%.hex: %.elf
    @echo
    @echo $(MSG_FLASH) $@
    $(OBJCOPY) -O $(FORMAT) -R .eeprom -R .fuse -R .lock $< $@

%.eep: %.elf
    @echo
    @echo $(MSG_EEPROM) $@
    -$(OBJCOPY) -j .eeprom --set-section-flags=.eeprom="alloc,load" \
    --change-section-lma .eeprom=0 --no-change-warnings -O $(FORMAT) $< $@ || exit 0

# Create extended listing file from ELF output file.
%.lss: %.elf
    @echo
    @echo $(MSG_EXTENDED_LISTING) $@
    $(OBJDUMP) -h -S -z $< > $@

# Create a symbol table from ELF output file.
%.sym: %.elf
    @echo
    @echo $(MSG_SYMBOL_TABLE) $@
    $(NM) -n $< > $@


# Create library from object files.
.SECONDARY : $(TARGET).a
.PRECIOUS : $(OBJ)
%.a: $(OBJ)
    @echo
    @echo $(MSG_CREATING_LIBRARY) $@
    $(AR) $@ $(OBJ)


# Link: create ELF output file from object files.
.SECONDARY : $(TARGET).elf
.PRECIOUS : $(OBJ)
%.elf: $(OBJ)
    @echo
    @echo $(MSG_LINKING) $@
    $(CC) $(ALL_CFLAGS) $^ --output $@ $(LDFLAGS)


# Compile: create object files from C source files.
$(OBJDIR)/%.o : %.c
    @echo

    @echo $(MSG_COMPILING) $<
                
    $(CC) -c $(ALL_CFLAGS) $< -o $@


# Compile: create object files from C++ source files.
$(OBJDIR)/%.o : %.cpp
    @echo
    @echo $(MSG_COMPILING_CPP) $<
    $(CC) -c $(ALL_CPPFLAGS) $< -o $@


Compile: create assembler files from C source files.
%.s : %.c
    $(CC) -S $(ALL_CFLAGS) $< -o $@


# Compile: create assembler files from C++ source files.
%.s : %.cpp
    $(CC) -S $(ALL_CPPFLAGS) $< -o $@


# Assemble: create object files from assembler source files.
$(OBJDIR)/%.o : %.S
    @echo
    @echo $(MSG_ASSEMBLING) $<
    $(CC) -c $(ALL_ASFLAGS) $< -o $@


# Create preprocessed source for use in sending a bug report.
%.i : %.c
    $(CC) -E -mmcu=$(MCU) -I. $(CFLAGS) $< -o $@


# Target: clean project.
clean: begin clean_list end

clean_list :
    @echo
    @echo $(MSG_CLEANING)
    $(REMOVE) $(TARGET).hex
    $(REMOVE) $(TARGET).eep
    $(REMOVE) $(TARGET).cof
    $(REMOVE) $(TARGET).elf
    $(REMOVE) $(TARGET).map
    $(REMOVE) $(TARGET).sym
    $(REMOVE) $(TARGET).lss
    $(REMOVE) $(SRC:%.c=$(OBJDIR)/%.o)
    $(REMOVE) $(SRC:%.c=$(OBJDIR)/%.lst)
    $(REMOVE) $(SRC:.c=.s)
    $(REMOVE) $(SRC:.c=.d)
    $(REMOVE) $(SRC:.c=.i)
    $(REMOVEDIR) .dep


# Create object files directory
$(shell mkdir $(OBJDIR) 2>/dev/null)


# Include the dependency files.
-include $(shell mkdir .dep 2>/dev/null) $(wildcard .dep/*)


# Listing of phony targets.
.PHONY : all begin finish end sizebefore sizeafter gccversion \
build elf hex eep lss sym coff extcoff \
clean clean_list program debug gdb-config

Bootloader

Fuses used FD:ex 5A:hi DF:lo (bit is set for bootloader address)

make file says 7800 for bootloader address.

chip mega 328

If I need to add more info let me know.

ok but 

So how can I determine the exact limit of the size. I'm just not certain how to calculate that. The number are all here. The complete source for the bootloader is available on line as pointed out in post #11. Is 7800 the lowest for 328?

I'm still not certain how this all adds up. With the data above I should be able to say max program size is x = b + p.

x= chip size (32k) 

b=botlaoder ( I think I can get this from post #11 with the new provided details)

p=program size (what is the size this needs to be under)

ok but my bootloader is 2k, so I must use at lease 01. And that is how its being used at the moment. 

so I see it this way

x= chip size (32k) 

b=botlaoder 2k

p=application must be less then or equal to 30k but its building at 28704 (see first post) Unless I missed something?

so I still have room but it says full when load with the bootloader. 

device size -00032768

data (28674) exceeds flash size!

flashing 28800 (0x7080) bytes  start at 0

Ok then I think we are getting close to the issue. So I use this. 

http://vusb.wikidot.com/project:...

maybe the code in this tool is set for a 4k assumption? - ill try to dig up the source. 

I was not very clear on the code when I started this but I now know that I have two flashing apps. 

bootloadflash and FW updater.

The source you see is FW updater. The code I'm using is bootloadflash. It is possible bootloadflash does not have that 2k limit but the source is tied up ATM. I can try to build from source and try the FW updater and see it that flashes. 

I'll also get the "Page Size = " and "Device Size = " output and report back. Thx for the help so far I'm getting closer here. 

Turns out the source forbootloadflash is gone lost forever according to the author. The main issue with FW updater is really hard to compile so I may not be able to make it work as things have changed so much over the years. 

So you are pretty sure the code is using something from the v-usb protect to determine the size? That I may be able to get answered. I'll contact Christian. But, from what I know this is a HID feature that sends data to the device. The feature report is how the usb sends the data. I think that like may just be a check for end of file or maybe an initial check for size 0. 

There is no way to get the source to the app I'm using.  If you want to disassemble it use this exe http://vusb.wikidot.com/project:...

Going to try using the bootloadhid now (source you are looking at). and see if I get the error.

good flash

Page size   = 128 (0x80)
Device size = 32768 (0x8000); 30720 bytes remaining
Uploading 28672 (0x7000) bytes starting at 0 (0x0)
0x06f80 ... 0x07000

bad flash

Page size   = 128 (0x80)
Device size = 32768 (0x8000); 30720 bytes remaining
Uploading 28800 (0x7080) bytes starting at 0 (0x0)
0x07000 ... 0x07080Error uploading data block: Communication error with device

Hi, thx for the interest to help me. So this latest zip with the ini. I'm not sure I'm using it right since there is no find button. I put my device in bootloader mode and I put in the vip/pid but it always says no device found. When the right id is put it does it just say found? Or do I have to hit enter or something?

Hi ok I'm following what you are saying a bit better now. At this time I don't wish to try USBbootAVR. I want to stay focused on the bootloader I have and getting this source to compile. If you ever finish what you said here.

I'm still working on the HID bootloader with your schematics, it still in progress.
Hope it will finish in few days.

I'd be very interested to try it.

That is too bad about source, I'd like to use that idea in my code. Would you consider helping me with my code at a later point? I'm not home right now but happy to test later.

I know the topic went a bit off here but I'm back on topic. Hope I still have a few watchers out there?

So I have the source compiled and now I see there is some type of issue here. At first look the error thrown is

 fprintf(stderr, "Error uploading data block: %s\n", usbErrorMessage(err));  - err says communication error...

but it should be

fprintf(stderr, "Data (%d bytes) exceeds remaining flash size!\n", endAddr);

or at least that makes more sense to me. But really I should not have any errors....

The endaddr is 28800 minus the bootloader size that's  26752 (6880)hex.

so I'm guessing the size is not the issue here... Looking closer at the error.

when  startAddr = 0x07000 and  startAddr + (int)sizeof(buffer.data.data) = 0x7080 It throws the comm error.

so I added a print above the error

[buffer.bytes]         [sizeof(buffer.data)]

2553172 ..................... 132

if usbSetReport is trowing this error I think the issue is in the bootloader hid code, no? If so my guess would be the usbFunctionWrite section because the set up is done.

setup looks like this

uchar   usbFunctionSetup(uchar data[8])
{
usbRequest_t    *rq = (void *)data;
static uchar    replyBuffer[7] = {
        1,                              /* report ID */
        SPM_PAGESIZE & 0xff,
        SPM_PAGESIZE >> 8,
        ((long)FLASHEND + 1) & 0xff,
        (((long)FLASHEND + 1) >> 8) & 0xff,
        (((long)FLASHEND + 1) >> 16) & 0xff,
        (((long)FLASHEND + 1) >> 24) & 0xff
    };

    if(rq->bRequest == USBRQ_HID_SET_REPORT){
        if(rq->wValue.bytes[0] == 2){
            offset = 0;
            return USB_NO_MSG;
        }
#if BOOTLOADER_CAN_EXIT
        else{
            exitMainloop = 1;
        }
#endif
    }else if(rq->bRequest == USBRQ_HID_GET_REPORT){
        usbMsgPtr = replyBuffer;
        return 7;
    }
    return 0;
}

while it sends data it will use the write function.

uchar usbFunctionWrite(uchar *data, uchar len)
{
union {
    addr_t  l;
    uint    s[sizeof(addr_t)/2];
    uchar   c[sizeof(addr_t)];
}       address;
uchar   isLast;

    address.l = currentAddress;
    if(offset == 0){
        DBG1(0x30, data, 3);
        address.c[0] = data[1];
        address.c[1] = data[2];
#if (FLASHEND) > 0xffff /* we need long addressing */
        address.c[2] = data[3];
        address.c[3] = 0;
#endif
        data += 4;
        len -= 4;
    }
    DBG1(0x31, (void *)&currentAddress, 4);
    offset += len;
    isLast = offset & 0x80; /* != 0 if last block received */
    do{
        addr_t prevAddr;
#if SPM_PAGESIZE > 256
        uint pageAddr;
#else
        uchar pageAddr;
#endif
        DBG1(0x32, 0, 0);
        pageAddr = address.s[0] & (SPM_PAGESIZE - 1);
        if(pageAddr == 0){              /* if page start: erase */
            DBG1(0x33, 0, 0);
#ifndef TEST_MODE
            cli();
            boot_page_erase(address.l); /* erase page */
            sei();
            boot_spm_busy_wait();       /* wait until page is erased */
#endif
        }
        cli();
        boot_page_fill(address.l, *(short *)data);
        sei();
        prevAddr = address.l;
        address.l += 2;
        data += 2;
        /* write page when we cross page boundary */
        pageAddr = address.s[0] & (SPM_PAGESIZE - 1);
        if(pageAddr == 0){
            DBG1(0x34, 0, 0);
#ifndef TEST_MODE
            cli();
            boot_page_write(prevAddr);
            sei();
            boot_spm_busy_wait();
#endif
        }
        len -= 2;
    }while(len);
    currentAddress = address.l;
    DBG1(0x35, (void *)&currentAddress, 4);
    return isLast;
}

nothing stands out? Only a guess here but maybe the usb descriptor is expecting a smaller size chip? Though I do see this comment about timers. /* compatibility with ATMega88 and other new devices: */ So I have to assume the author expects 328's here.

Also I see a few cli's in the bootload code, I wonder if its taking too long and dropping? - doubtful.

interestingly changing  to  if(endAddr > deviceSize - 1024) didnt change a thing, so I'm sure this it not a size issue. Really confused at this point.

Two more additional points of interest.  I tried adding a loop to slow it down and it still failed at the same point. Also if I interrupt the usb transfer I can the same error. The failing at the same point every time is what makes thing confusing. Though this is a clue to what is causing the issue and should be easier to track down and fix as its religiously repeatable.