I am seriously thinking of putting an ext3 partition onto my 512Mb SD card but being of the cautious type I decided to do a little digging.
Firstly a comparison of the existing partition table between a desktop card reader and an SL-C860.
On SuSE 9.1 through Dazzle USB 2 card reader (fdisk -v reports 2.12)The number of cylinders for this disk is set to 13895.
There is nothing wrong with that, but this is larger than 1024,
and could in certain setups cause problems with:
1) software that runs at boot time (e.g., old versions of LILO)
2) booting and partitioning software from other OSs
(e.g., DOS FDISK, OS/2 FDISK)
Command (m for help): p
Disk /dev/sda: 512 MB, 512229376 bytes
9 heads, 8 sectors/track, 13895 cylinders
Units = cylinders of 72 * 512 = 36864 bytes
Device Boot Start End Blocks Id System
/dev/sda1 4 13896 500107+ 6 FAT16
Command (m for help):
On Zaurus SL-C860 running Cacko 1.21b (fdisk -v reports v2.11g)# fdisk /dev/mmcda
Command (m for help): p
Disk /dev/mmcda: 16 heads, 63 sectors, 992 cylinders
Units = cylinders of 1008 * 512 bytes
Device Boot Start End Blocks Id System
/dev/mmcda1 1 993 500107+ 6 FAT16
Partition 1 does not end on cylinder boundary:
phys=(992, 8,

should be (992, 15, 63)
Command (m for help):
Observations 1Notice that the geometry reported is quite different between the two outputs. I then decided to have a look at the changelog for fdisk from the util-linux package and found that the versioning goes from 2.11g through 2.11z before it gets to 2.12 with MANY changes to fdisk including improved geometry stuff.
Having built a new copy of fdisk this is the observation...
On Zaurus SL-C860 running Cacko 1.21b with fdisk built from util-linux-2.12a# ./fdisk-2.12a /dev/mmcda
The number of cylinders for this disk is set to 13895.
There is nothing wrong with that, but this is larger than 1024,
and could in certain setups cause problems with:
1) software that runs at boot time (e.g., old versions of LILO)
2) booting and partitioning software from other OSs
(e.g., DOS FDISK, OS/2 FDISK)
Command (m for help): p
Disk /dev/mmcda: 512 MB, 512229376 bytes
9 heads, 8 sectors/track, 13895 cylinders
Units = cylinders of 72 * 512 = 36864 bytes
Device Boot Start End Blocks Id System
/dev/mmcda1 4 13896 500107+ 6 FAT16
/dev/mmcda2 1 1 0 0 Empty
Partition 2 does not end on cylinder boundary.
Command (m for help):
Observations 2This is the interesting thing, the new version of fdisk reports the start block for mmcda1 at block 4 and also reports a secondary partition of 1 block at block 1. Could this be storing some metadata for the card that's getting zapped if people repartition with the older fdisk

What are your thoughts people ?
By the way I'm still not completely happy with flattening it and going ext3 yet.