This may be an jffs2 issue. Maybe your kernel uses a compression that the kexecboot kernel doesn't have. So if you write much data your jffs2-driver uses the new compression to recompress some data from the kernels.

If you only install some packages at a time, jffs2 might only use free space and doesn't do any complex recompression stuff.

But thats just a theory ;)

Regards,
Thomas

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